Professional Documents
Culture Documents
Dokumen - Tips Cat 3516 B and 3516 B High Displacement Engines Troubleshooting Caterpillar
Dokumen - Tips Cat 3516 B and 3516 B High Displacement Engines Troubleshooting Caterpillar
RENR5622
September 2005
Troubleshooting
3516B and 3516B High Displacement
Engines for Caterpillar Built Machines
FDB1-Up (Machine)
8WM1-Up (Engine)
7TR1-Up (Engine)
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 1/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
i01658146
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 “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The message that appears under the warning explains the hazard and can be either 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
is used, you must satisfy yourself that it is 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
repair 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, torques, pressures,
measurements,
affect the serviceadjustments,
that is given illustrations,
to the product.and otherthe
Obtain items can change
complete at any
and most time. These
current changes
information canyou
before
start any job. Caterpillar dealers have the most current information available.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 2/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 3
Table of Contents
Display Modules
Electronic Service..................................................
Tool Will Not Communicate with43
ECM .................................................................... 44
Engine Cranks but Will Not Start .......................... 45
Engine Has Early Wear ........................................ 46
Engine Misfires, Runs Rough or Is Unstable ........ 47
Engine Oil in Cooling System ............................... 48
Engine Overspeed ................................................ 48
Engine Stalls at Low RPM .................................... 49
Engine Will Not Crank ........................................... 50
Excessive Engine Oil Consumption ...................... 51
Excessive Black Smoke ........................................ 51
Excessive White Smoke ....................................... 53
Exhaust Temperature Is Too High ......................... 54
Fuel Dilution
Fuel in of System
Cooling Engine Oil .................................... 55
......................................... 55
Inlet Air Restriction ................................................ 55
Intermittent Engine Shutdown ............................... 56
Intermittent Low Power or Power Cutout .............. 57
Low Engine Oil Pressure ...................................... 58
Low Power/Poor or No Response to Throttle ....... 59
Mechanical Noise (Knock) in Engine .................... 61
Noise Coming from Cylinder ................................. 61
Poor Fuel Consumption ........................................ 62
Too Much Valve Lash ............................................ 63
Too Much Vibration ............................................... 64
Valve Rotocoil or Spring Lock Is Free ................... 64
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 3/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
4 RENR5622
Troubleshooting Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 4/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 5
Troubleshooting Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 5/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
6 RENR5622
Troubleshooting Section
g01206901
Illustration 1
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 6/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 7
Troubleshooting Section
Typical schematic
g01206905
Illustration 2
Typical schematic
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 7/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
8 RENR5622
Troubleshooting Section
g01206909
Illustration 3
Typical schematic
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 8/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 9
Troubleshooting Section
g01208645
Illustration 4
Front and Left view
(1) Turbocharger compressor outlet (5) Left turbocharger compressor inlet (12) Connector for the remote shutdown
pressure sensor (boost) pressure sensor (13) Low oil level switch
(2) Aftercooler temperature sensor (front) (7) Fuel filter differential pressure switch (14) Unfiltered engine oil pressure sensor
(3) Right turbocharger compressor inlet (8) Filtered engine oil pressure sensor (15) Atmospheric pressure sensor
pressure sensor (9) ECM connector J1/P1 (16) ECM connector J2/P2
(4) Coolant temperature sensor (10) Machine connector (17) Engine speed/timing sensor
(6) Left exhaust temperature sensor (11) Connection for the prelube
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 9/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
10 RENR5622
Troubleshooting Section
g01208648
Illustration 5
Rear and Right view
(18) Aftercooler temperature sensor (rear) (22) Crankcase pressure sensor
(19) Right exhaust temperature sensor (23) Connector for the engine oil renewal
(20) Connector for the wastegate solenoid solenoid
(21) Timing calibration plug (24) Coolant flow switch
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 10/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 11
Troubleshooting Section
• Diagnostic Code
• Event Code
Diagnostic Code – A diagnostic code indicates an
electrical problem such as a short or an open in the
engine’s wiring or in an electrical component of the
engine.
• Active
• Logged
Active Codes
An active code indicates that a problem is present.
Service the active code first. For the appropriate
troubleshooting procedure for a particular code, refer
to the following troubleshooting procedure:
Logged Codes
The codes are logged and stored in the ECM
memory. The problem may have been repaired
and/or the problem may no longer exist. If the
system is powered, it is possible to generate an
active diagnostic code whenever a component is
disconnected. If the component is reconnected, the
code is no longer active but the code may become
logged.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 11/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
12 RENR5622
Troubleshooting Section
i02414932
g01158941
Illustration 6
Connectors for the ECM
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 12/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 13
Troubleshooting Section
Machine Connector
g01207090
Illustration 7
40 pin machine connector
g01158896
Illustration 8
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 13/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
14 RENR5622
Troubleshooting Section
Sensor Connectors
g01207085
Illustration 9
Typical engine connectors
i02419684
• Obtain data.
• Diagnose problems.
• Read parameters.
• Program parameters.
• Calibrate sensors.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 14/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 15
Troubleshooting Section
Two short jumper wires are needed to check the Part Description
continuity of some wiring harness circuits by shorting Number
two adjacent terminals together in a connector. A
N/A Personal Computer (PC)
long extension wire may also be needed to check the
continuity of some wiring harness circuits.
JERD2124 Single user license for Cat ET
• Parameters
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 15/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
16 RENR5622
Troubleshooting Section
Connecting Cat ET and the 4. Restore electrical power to the ECM. If Cat ET and
Communication Adapter II the communication adapter do not communicate
with the Electronic Control Module (ECM), refer
to troubleshooting without a diagnostic code
Troubleshooting, “Electronic Service Tool Will Not
Communicate with ECM”.
i02415084
g01115382
Illustration 10
(1) Personal computer (PC)
(2) 196-0055 Adapter Cable As
(3) 171-4401 Communication Adapter As
(4) 207-6845 Adapter Cable As
Note: Items (2), (3), and (4) are part of the 171-4400
Communication Adapter Gp.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 16/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 17
Troubleshooting Section
Table 4
MID 0036 - CID 0001 - FMI 06 Cylinder #1 Injector short “Injector Solenoids”
MID 0036 - CID 0002 - FMI 05 Cylinder #2 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0002 - FMI 06 Cylinder #2 Injector short “Injector Solenoids”
MID 0036 - CID 0003 - FMI 05 Cylinder #3 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0003 - FMI 06 Cylinder #3 Injector short “Injector Solenoids”
MID 0036 - CID 0004 - FMI 05 Cylinder #4 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0004 - FMI 06 Cylinder #4 Injector short “Injector Solenoids”
MID 0036 - CID 0005 - FMI 05 Cylinder #5 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0005 - FMI 06 Cylinder #5 Injector short “Injector Solenoids”
MID 0036 - CID 0006 - FMI 05 Cylinder #6 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0006 - FMI 06 Cylinder #6 Injector short “Injector Solenoids”
MID 0036 - CID 0007 - FMI 05 Cylinder #7 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0007 - FMI 06 Cylinder #7 Injector short “Injector Solenoids”
MID 0036 - CID 0008 - FMI 05 Cylinder #8 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0008 - FMI 06 Cylinder #8 Injector short “Injector Solenoids”
MID 0036 - CID 0009 - FMI 05 Cylinder #9 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0009 - FMI 06 Cylinder #9 Injector short “Injector Solenoids”
MID 0036 - CID 0010 - FMI 05 Cylinder #10 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0010 - FMI 06 Cylinder #10 Injector short “Injector Solenoids”
MID 0036 - CID 0011 - FMI 05 Cylinder #11 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0011 - FMI 06 Cylinder #11 Injector short “Injector Solenoids”
MID 0036 - CID 0012 - FMI 05 Cylinder #12 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0012 - FMI 06 Cylinder #12 Injector short “Injector Solenoids”
MID 0036 - CID 0013 - FMI 05 Cylinder #13 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0013 - FMI 06 Cylinder #13 Injector short “Injector Solenoids”
MID 0036 - CID 0014 - FMI 05 Cylinder #14 Injector open “Injector Solenoids”
circuit
MID 0036 - CID 0014 - FMI 06 Cylinder #14 Injector short “Injector Solenoids”
MID 0036 - CID 0015 - FMI 05 Cylinder #15 Injector open “Injector Solenoids”
circuit
(continued)
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 17/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
18 RENR5622
Troubleshooting Section
(Table 4, contd)
MID 0036 - CID 0262 - FMI 04 5 Volt Sensor DC Power “Sensor Supply”
Supply short to ground
MID 0036 - CID 0263 - FMI 03 Digital Sensor Supply short “Sensor Supply”
to +batt
MID 0036 - CID 0263 - FMI 04 Digital Sensor Supply short “Sensor Supply”
to ground
MID 0036 - CID 0267 - FMI 02 Incorrect Engine Shutdown “Ground Level Shutdown Switch”
Switch inputs
MID 0036 - CID 0268 - FMI 02 Check Programmable “System Configuration Parameters”
Parameters
MID 0036 - CID 0273 - FMI 03 Turbo Outlet Pressure “Analog Sensor (Active)”
open/short to +batt
MID 0036 - CID 0273 - FMI 04 Turbo Outlet Pressure short “Analog Sensor (Active)”
to ground
MID 0036 - CID 0274 - FMI 03 Atmospheric Pressure “Analog Sensor (Active)”
open/short to +batt
MID 0036 - CID 0274 - FMI 04 Atmospheric Pressure short “Analog Sensor (Active)”
to ground
MID 0036 - CID 0275 - FMI 03 Right Turbo Inlet Pressure “Analog Sensor (Active)”
open/short to +batt
(continued)
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 18/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 19
Troubleshooting Section
(Table 4, contd)
MID 0036 - to
open/short CID 0276 - FMI 03 Left Turbo Inlet Pressure
+batt “Analog Sensor (Active)”
MID 0036 - CID 0276 - FMI 04 Left Turbo Inlet Pressure “Analog Sensor (Active)”
short to ground
MID 0036 - CID 0279 - FMI 03 Aftercooler Temperature “Analog Sensor (Active)”
open/short to +batt
MID 0036 - CID 0279 - FMI 04 Aftercooler Temperature short “Analog Sensor (Active)”
to ground
MID 0036 - CID 0296 - FMI 09 Unable to communicate with “Cat Data Link”
Transmission ECM
MID 0036 - CID 0338 - FMI 05 Pre-lube Relay open circuit “Prelubrication System”
MID 0036 - CID 0338 - FMI 06 Pre-lube Relay short to ground “Prelubrication System”
MID 0036 - CID 0526 - FMI 05 Turbo Wastegate Drive “Wastegate Solenoid”
current low
MID 0036 - CID 0526 - FMI 06 Turbo Wastegate Drive “Wastegate Solenoid”
current high
MID 0036 - CID 0542 - FMI 03 Unfiltered Engine Oil Pressure “Analog Sensor (Active)”
open/short to +batt
MID 0036 - CID 0542 - FMI 04 Unfiltered Engine Oil Pressure “Analog Sensor (Active)”
short to ground
MID 0036 - CID 0543 - FMI 03 Filtered Engine Oil Pressure “Analog Sensor (Active)”
open/short to +batt
MID 0036 - CID 0543 - FMI 04 Filtered Engine Oil Pressure “Analog Sensor (Active)”
short to ground
MID 0036 - CID 0545 - FMI 05 Ether Start Relay open/short “Ether Injection System”
to +batt
MID 0036 - CID 0545 - FMI 06 Ether Start Relay short to “Ether Injection System”
ground
MID 0036 - CID 0546 - FMI 05 Ether Hold Relay open/short “Ether Injection System”
to ground
MID 0036 - CID 0546 - FMI 06 Ether Hold Relay short to +batt “Ether Injection System”
MID 0036 - CID 0569 - FMI 05 Oil Renewal Solenoid open “Engine Oil Renewal Solenoid”
circuit
MID 0036 - CID 0569 - FMI 06 Oil Renewal Solenoid short “Engine Oil Renewal Solenoid”
to ground
MID 0036 - CID 0800 - FMI 09 Unable to communicate with “Cat Data Link”
VIMS
MID 0036 - CID 0827 - FMI 08 Left Exhaust Temperature “Pulse Width Modulated Sensor”
signal abnormal
MID 0036 - CID 0828 - FMI 08 Right Exhaust Temperature “Pulse Width Modulated Sensor”
signal abnormal
MID 0036 - CID 0829 - FMI 03 Rear Aftercool Temperature “Analog Sensor (Active)”
open/short to +batt
(continued)
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 19/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
20 RENR5622
Troubleshooting Section
(Table 4, contd)
FMI Failure
Diagnostic codes alert the operator that a problem in
the electronic system has been detected. Diagnostic 00 Data is above the normal
codes also indicate the nature of the problem to range.
the service technician. The Caterpillar Electronic 01 Data is below the normal
Technician (ET) is a software program that is range.
designed to run on a personal computer. Diagnostic
codes may be viewed on a personal computer that 02 Incorrect signal
has Cat ET software. Diagnostic codes consist of 03 Voltage is above the
the module
(CID), identifier
and the failure(MID), the component
mode identifier (FMI). identifier normal range.
04 Voltage is below the normal
range.
Component Identifier (MID) – The MID is a three
digit code that identifies the Electronic Control 05 Current is below the normal
Module (ECM) that generated the diagnostic code. range.
For example, the CID number 036 identifies the
06 Current is above the
engine ECM.
normal range.
13 A component is out of
Failure Mode Identifier (FMI) – The FMI is a two calibration.
digit code that indicates the type of failure. Refer to
Table 5 for a complete list of the two digit codes.
Refer to Table 5 for a description of the failure. Refer to Table 4 for a complete list of the diagnostic
codes and the appropriate troubleshooting procedure.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 20/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 21
Troubleshooting Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 21/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
22 RENR5622
Troubleshooting Section
Table 6
E100 Low Engine Oil Pressure Warning “Low Engine Oil Pressure”
E101 High Crankcase Pressure Warning “Crankcase Pressure (High)”
E190 Engine Overspeed Warning “Engine Overspeed”
E265 User Defined Shutdown “User Defined Shutdown Input”
E272 Inlet Air Restriction Warning “Inlet Air Restriction”
E279 High Aftercooler Temperature Warning “Coolant Temperature Is Too High”
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 22/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 23
Troubleshooting Section
g01138880
• The number of occurrences of the code
Illustration 12
Example of the typical operating range of a temperature sensor Logged events are listed in chronological order. The
(1) This area represents the normal operating range of the most recent event code is listed first.
parameter. The normal output voltage of the sensor is between
0.2 VDC and 4.2 VDC. This information can be helpful for troubleshooting
(2) In this area, the temperature above 107 °C (225 °F) is higher intermittent problems. Logged codes can also be
than normal. The output voltage of the sensor will generate an
event code. The sensor does not have an electronic problem.
used to review the performance of the engine.
(3) In these areas, the output voltage of the sensor is too high
or too low. The voltage is outside of the normal range. The
electronic problem will generate a diagnostic code. Refer
Clearing Event Codes
to Troubleshooting, “Diagnostic Code List” for additional
information on diagnostic codes. A code is cleared from memory when one of the
following conditions occur:
Events are represented in two formats. In the first
format, the “E” means that the code is an event • The code does not recur for 100 hours.
code. The “XXX” represents a numeric identifier for
the event code. This is followed by a description of • A new code is logged and there are already ten
the code. If a warning, a derate, or a shutdown is codes in memory. In this case, the oldest code is
applicable, the numeric identifiers are different. Refer cleared.
to the following example:
• The service technician manually clears the code.
• E004 Engine Overspeed Shutdown
Always clear logged event codes after investigating
In the second format, the “E” means that the code is and correcting the problem which generated the
an event code. The “XXX-X” represents a numeric code.
identifier for the event code. The fourth “X” identifies
the event as a warning, a derate, or a shutdown. This
is followed by a description of the code. Refer to the
following example:
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 23/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
24 RENR5622
Troubleshooting Section
• Fuel supply
• Oil level
• Oil supply
• Wiring
• Connectors
Be sure to check the connectors. This is very
important for problems that are intermittent. Refer to
Troubleshooting, “Inspecting Electrical Connectors”.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 24/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 25
Troubleshooting Section
Table 7
pressure.
E095 Fuel Filter 138 °C
Warning N/A N/A N/A N/A N/A On
Restriction Warning (280 °F)
E098 Engine Prelube The engine
Override has started
without
Warning N/A N/A N/A N/A N/A On
completing
the engine
prelubrication.
Map
E100 Low Engine Oil
Warning 1 15 4 N/A N/A dependent On
Pressure
value (3)
E101 High Crankcase 0.5 kPa 6 kPa
Warning 1 60 3 2 kPa ( 0.3 p si) On
Pressure (0.07 psi) (0.9 psi)
E190 Engine Overspeed Warning N/A N/A 0 1200 rpm 2400 rpm 2200 rpm On
E265 User Defined
Warning N/A N/A 1 N/A N/A Closed On
Shutdown
3 kPa 7 kPa
E272 Inlet Air Restriction Warning 1 60 5 7 kPa (1 psi) On
(0.4 psi) (1 psi)
E279 High Aftercooler 40 °C 102 °C 102 °C
Warning 1 60 5 On
Temperature (104°F) (216 °F) (216 °F)
(1) The ECM derates the engine in 15 second intervals in 2 percent increments when the exhaust temperature is over the trip point. The
maximum derate is 20 percent.
(2) The fuel is derated by 30 percent. The timing is retarded to four degrees before top dead center. The code is latched until power
is cycled to the ECM.
(3)
Refer to Illustration 13.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 25/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
26 RENR5622
Troubleshooting Section
g01210600
Illustration 13
Low oil pressure map
Table 8
E021 High Exhaust Temperature Derate The exhaust temperature is above the The code is active and the code is
trip point temperature for five seconds. logged.
The ramp rate of the derate is 2 percent
per 15 seconds.
The maximum derate is 20 percent.
E035 Loss of Coolant Flow Warning The coolant flow switch opens. The code is active and the code is
logged.
E038 Low Engine Coolant Temperature The coolant temperature is below the The code is active and the code is
Warning trip point temperature for five seconds. logged.
(continued)
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 26/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 27
Troubleshooting Section
(Table 8, contd)
E073
High Oil Filter Differential Pressure The
aboveoilthe
filter
tripdifferential pressure is
point temperature. The code is active and the code is
logged.
The warning for the oil filter differential
E074 Oil Filter Differential Pressure pressure is determined by subtracting
Very High the filtered oil pressure from the
unfiltered oil pressure.
E092 Boost Pressure Above Normal The actual boost pressure is above the The code is active and the code is
desired boost pressure by the trip point logged.
pressure. The fuel is derated by 30 percent. The
Engine speed is between 1275 and timing is retarded to four degrees before
1800 rpm. top dead center. The code is latched
until power is cycled to the ECM.
E093 Boost Pressure Below Normal The actual boost pressure is below the The code is active and the code is
desired boost pressure by the trip point logged.
pressure.
Engine speed is between 1275 and The
timingfuel
is is derated
retarded toby 30degrees
four percent.before
The
1800 rpm. top dead center. The code is latched
until power is cycled to the ECM.
E095 Fuel Filter Restriction Warning The restriction across the fuel filter is The code is active and the code is
greater than the trip point pressure. The logged.
fuel filter differential pressure switch
opens.
E098 Engine Prelube Override The engine has started without The code is active and the code is
completing the engine prelubrication. logged.
E100 Low Engine Oil Pressure Warning The engine oil pressure is below a map The code is active and the code is
dependent value. The oil pressure is logged.
below this value for the delay time.
E101 High Crankcase Pressure Engine crankcase pressure is above The code is active and the code is
Warning trip point pressure for the delay time. logged.
E190 Engine Overspeed Warning The engine rpm has exceeded the trip The code is active and the code is
point for engine overspeed for the delay logged.
time.
E265 User Defined Shutdown The ECM detects ground on the input The code is active and the code is
for the user defined shutdown. logged.
E272 Inlet Air Restriction Warning The inlet air restriction is above the trip The code is active and the code is
point pressure for the delay time. logged.
E279 High Aftercooler Temperature The aftercooler temperature is above The code is active and the code is
Warning the trip point temperature for the delay logged.
time.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 27/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
28 RENR5622
Troubleshooting Section
Programming Parameters Note: The old interlock code and the new interlock
code are required to change the interlock code on a
used Electronic Control Module (ECM).
i01951720
The Cat ET screen for factory passwords will display
Programming Parameters the following parameters:
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 28/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 29
Troubleshooting Section
• Engine hours
Note: Engine hours do not include service meter
hours.
Table 9
i02414553
Flash Programming
SMCS Code: 1901-038
Table 10
Program the correct flash file into the engine’s ECM. Caterpillar Electronic Technician (ET) is used to flash
program a file into the memory of the engine’s ECM.
Flash Programming – This is a method of
programming or updating the flash file in an engine’s
ECM.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 29/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
30 RENR5622
Troubleshooting Section
If you do not have the flash file, use the “Flash File i02416716
Search” tool on the Service Technician Workbench
(STW) to obtain the flash file for your engine. System Configuration
Alternatively, use the “Service Software Files” feature Parameters
on SIS Web to obtain the flash file for your engine.
You must have the engine serial number in order to SMCS Code: 1901-038
search for the flash file. After locating the correct
flash file, download the flash file to your PC. Write Use this procedure if any one of the diagnostic codes
down the name of the flash file for future reference. in Table 11 is active.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 30/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 31
Troubleshooting Section
Table 11
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 31/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
32 RENR5622
Troubleshooting Section
Parameter Table
Table 12
- Rating”
(1) (1)
“Personality Module interlock Yes
- ECM”
“Prelube” Disabled Enabled Yes
Disabled
“Shutter Control” Disabled Enabled No
Disabled
(1) The “Personality Module” interlock is automatically programmed by the ECM after factory passwords have been entered.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 32/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 33
Troubleshooting Section
Table 13
i02418875 Table 15
“Inj #2 e-trim”
SMCS Code: 1901-038
“Inj #3 e-trim”
Table 14
“Inj #4 e-trim”
System Configuration Parameters
“Inj #5 e-trim”
Parameter Worksheet
“Inj #6 e-trim”
“Engine Serial Number”
“Inj #7 e-trim”
“Equipment ID”
“Inj #8 e-trim”
“Full Load Setting (FLS)”
“Inj #9 e-trim”
“Cold Cylinder Cutout”
“Inj #10 e-trim”
“Fuel Ratio Control Offset”
“Ether Control” “Inj #11 e-trim”
“Inj #12 e-trim”
“Oil Renewal”
“Inj #13 e-trim”
“Personality Module
“Inj #14 e-trim”
interlock - Rating”
“Inj #15 e-trim”
“Personality Module
interlock - ECM” “Inj #16 e-trim”
“Prelube Control”
“Shutter Control”
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 33/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
34 RENR5622
Troubleshooting Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 34/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 35
Troubleshooting Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 35/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
36 RENR5622
Troubleshooting Section
5. Check the wiring and the connectors for the Check the condition of the alternator drive pulley.
following problems: Look
pulleyfor
bydeep grooves
the belt. that
If there is have been wear,
excessive worn into the
replace
• Damage the pulley. Check that the nut for the pulley has not
become loose. If necessary, tighten the nut.
• Abrasion
Alternator Bearings
• Corrosion
Check the alternator bearings for signs of wear.
• Incorrect attachment Repair the alternator or replace the alternator, as
needed.
6. Check for any logged diagnostic codes.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 36/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 37
Troubleshooting Section
i02418528
Table 16
Event Code
Description Conditions which Generate this Code System Response
E092 Boost Pressure Above Normal The actual boost pressure is above the The code is logged and the code is
desired boost pressure. active.
Probable Causes
Recommended Actions
Leaking Wastegate Diaphragm
Verify that the exhaust bypass valve for the wastegate
can open. Use Caterpillar Electronic Technician (ET)
to override the wastegate to 100 percent. Perform a
torque converterevent
boost pressure stall test.
shouldAfter 30 seconds,
result. a low
If a low boost
pressure event occurs, the wastegate is opening
properly.
Air Supply
Verify that the air supply to the wastegate control
valve is at least 345 kPa (50 psi).
Wrong FLS
Check that the FLS is correct.
i02418529
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 37/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
38 RENR5622
Troubleshooting Section
Table 17
Event Code
Description Conditions which Generate this Code System Response
E093 Boost Pressure Below Normal The actual boost pressure is below the The code is logged and the code is
desired boost pressure. active.
• Work on the low pressure fuel supply circuit Engine Speed/Timing Signal
• Replace the fuel injectors. Check Cat ET for the following logged Diagnostic
Code 190-08. Refer to the diagnostic functional test
b. Purge air from the fuel system with the priming Troubleshooting, “Engine Speed/Timing Sensor”.
pump and by cranking the engine in 30 second
cycles. After you crank the engine, stop for two
minutes. This will allow the starting motor to
Active Engine Derate
cool. Loosen the vent plug at the fuel return.
Connect Cat ET and check for “ACTIVE” engine
The plug is located on the rear upper left side
derates. If the active engine derate is due to “Axle
of the engine block. Prime the engine again if
Protection”, refer to the Service Manual for the
air in fuel continues. A sight glass in the low
transmission or implement control. Perform the
pressure supply line is helpful in diagnosing
torque converter stall test. Compare the achieved
air in the fuel.
stall speed to specifications. If the output meets
specifications, continue with diagnostic checks.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 38/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 39
Troubleshooting Section
Note: If this problem occurs under load, refer to Check fuel lines for the following problems:
the diagnostic procedure Troubleshooting, “Low restrictions, collapse, and pinched line. Repair the
Power/Poor Or No Response To Throttle”. lines and/or replace the lines.
• Leaks in air system 3. Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer
• Valve adjustment to the Systems Operation/Testing and Adjusting
manual for the correct pressure values. If the fuel
• Injectors pressure is low, replace the fuel filters. If the fuel
pressure is still low, check the following items: fuel
• Faulty accessory equipment transfer pump, fuel transfer pump coupling, and
fuel pressure regulating valve.
Recommended Actions
Air Inlet Restriction
Derate
Replace plugged air filters and/or clean the filters.
Connect Caterpillar Electronic Technician (ET) and Leaks in the air inlet manifold system can lower Inlet
check for an active derate event. A derate status manifold pressure.
flag will appear on Cat ET if an active engine derate
is occurring. In order to view active events, go to Exhaust Restriction
the “Events” menu under “Diagnostics”. Refer to
Troubleshooting, “Troubleshooting with an Event Check the exhaust system for restrictions and/or for
Code” for the specific events for this application. leaks.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 39/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
40 RENR5622
Troubleshooting Section
i02423560
i02338332
Coolant Temperature Is Too
Coolant in Engine Oil
Low
SMCS Code: 1300-038; 1901-038 SMCS Code: 1350-038; 1901-038
Probable Causes Use this procedure in order to troubleshoot a
low coolant temperature or use this procedure
• Failure of the oil cooler core if the following event code is active. Refer to
Troubleshooting, “Event Code List” for information on
• Failure of cylinder head gasket specific trip points for the event codes.
• Water pump
Recommended Actions
Failure of Oil Cooler Cores
Inspect the oil cooler for leaks. Make repairs, as
needed. Drain the crankcase. Refill the crankcase
with clean lubricant. Change the oil filters.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 40/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 41
Troubleshooting Section
Table 18
Event Code
Description Conditions which Generate this Code System Response
E038 Low Engine Coolant Temperature The coolant temperature is below the The code is active and the code is
Warning trip point. logged.
Probable Causes
• Faulty water temperature regulator
• Long idle periods
• Very light loads
Recommended Actions
Water Temperature Regulator
i02416900
Table 19
Event Code
Description Conditions which Generate this Code System Response
E017 High Engine Coolant Temperature The engine coolant temperature is The code is active and the code is
Warning above the trip point temperature. logged.
E279 High Aftercooler Temperature The aftercooler temperature is above
Warning the trip point temperature.
• Faulty radiator cooling fan (if equipped) Faulty Jacket Water Coolant Pump
• Faulty pressure relief valve Inspect the impeller vanes at the jacket water pump
for damage and/or for erosion. Repair impeller vanes
• Faulty temperature regulator and/or replace the impeller vanes.
Coolant Leak
Check the cooling system for leaks.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 42/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 43
Troubleshooting Section
Table 20
Event Code
Description Conditions which Generate this Code System Response
E101 High Crankcase Pressure Engine crankcase pressure is above The code is active and the code is
Warning the trip point for high pressure. logged.
Start the engine. If the engine starts, but the ECM Cat ET and Related Hardware
will not communicate with Cat ET, continue with
this procedure. If the engine will not start, refer to In order to eliminate Cat ET and the related hardware
Troubleshooting, “Engine Cranks but Will Not Start”. as the problem, connect Cat ET to a different engine.
If the engine will not crank, refer to Troubleshooting, If the same problem occurs on a different engine,
“Engine Will Not Crank”. check Cat ET and the related hardware in order to
determine the cause of the problem.
Configuration for the Communications
Adapter Electrical Power Supply to the Electronic
Control Module (ECM)
1. Access “Preferences” under the “Utilities” menu
on Cat ET. Check power to the ECM. Refer to Troubleshooting,
“Electrical Power Supply”.
2. Verify
Device”that the correct “Communications Interface
is selected. Note: If the ECM is not receiving battery voltage, the
ECM will not communicate.
3. Verify that the correct port is selected for use by
the communication adapter.
Flash File
Note: The most commonly used port is “COM 1”.
Ensure that the correct flash file is properly installed
in the ECM.
4. Check for any hardware that is utilizing the
same port as the communications adapter. If any
devices are configured to use the same port, exit
or close the software programs for that device.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 44/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 45
Troubleshooting Section
Note: The new ECM does not have a flash file. Starting Aids
The engine will not start and the engine will not
communicate with Cat ET until the flash file has 1. If cold ambient conditions exist, check operation
been installed. Refer to Troubleshooting, “Flash of starting aids. Verify that the ether system is
Programming”. operating correctly. Refer to Troubleshooting,
“Ether Injection System”.
Cat Data Link
2. Ensure the proper operation of the jacket water
Troubleshoot the Cat Data Link for possible problems. heater. Repair the jacket water heater and/or
Refer to Troubleshooting, “Cat Data Link”. replace the jacket water heater, if necessary.
Engine Cranks but Will Not Engine Shutdown Switches (If Equipped)
Start The engine shutdown switches should be in the
OFF position. Use Cat ET to verify the status of the
SMCS Code: 1000-038; 1901-038 shutdown switches. When a shutdown occurs, the
keyswitch must be turned to the OFF position for at
Probable Causes least 15 seconds before restarting the engine.
• Event codes 1. Crank the engine and observe the engine speed
on the Cat ET status screen. If Cat ET indicates
• Electrical power supply to the Electronic Control zero rpm, refer to Troubleshooting, “Engine
Module (ECM) Speed/Timing Sensor”.
• Starting aids (if applicable) Note: Upon initial cranking, the status for engine
speed may indicate that the engine speed signal is
• Engine shutdown switches abnormal. This message will be replaced with an
engine speed once the ECM is able to calculate a
• Engine speed/timing speed from the signal.
3. Check the fuel tank for foreign objects which may Recommended Actions
block the fuel supply.
Incorrect Engine Oil
NOTICE
Do not crank the engine continuously for more than Use engine oil that is recommended and change the
30 seconds. Allow the starting motor to cool for two engine oil at the interval that is recommended by the
minutes before cranking the engine again. engine’s Operation and Maintenance Manual.
Engine Has Early Wear An indicator for the engine oil pressure may indicate
sufficient pressure, but a component is worn due to a
SMCS Code: 1000-038; 1901-038 lack of lubrication. In such a case, look at the passage
for
thethe engineOperation/Testing
Systems oil supply to the component. Refer
and Adjusting to
manual
Probable Causes for additional information.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 46/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 47
Troubleshooting Section
SMCS Code: 1000-038; 1901-038 2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
Note: If the symptom is intermittent and the symptom are being energized by the ECM.
cannot be repeated, refer to Troubleshooting,
“Intermittent Low Power or Power Cutout”. If the 3. Perform the “Cylinder Cutout Test” on Cat ET in
symptom is consistent and the symptom can be order to identify any misfiring cylinder(s). Refer
repeated, continue with this procedure. to Troubleshooting, “Injector Solenoids” for more
information.
Probable Causes
• Engine oil cooler core
• Cylinder head gasket
• Water pump
Recommended Actions
Engine Oil Cooler Core
1. Inspect the engine oil cooler core for leaks. If a
leak is found, replace the oil cooler core. Refer to
Disassembly and Assembly.
Water Pump
Check the weep hole in the water pump for blockage.
Check the water pump seals.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 48/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 49
Troubleshooting Section
Table 21
Event Code
Description Conditions which Generate this Code System Response
E190 Engine Overspeed Warning The engine rpm is above the trip point The code is active and the code is
for overspeed. logged.
Sudden Drop of Load 2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
Decrease the load on the engine gradually. problems are found with the fuel lines, repair the
lines and/or replace the lines.
i02385598
3. Check the fuel tank for foreign objects which may
Engine Stalls at Low RPM block the fuel supply.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 49/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
50 RENR5622
Troubleshooting Section
6. Check the fuel pressure after the fuel filter while • Internal engine problem
the engine is being cranked. Refer to the Systems
Operation/Testing and Adjusting manual for the
correct pressure values. If the fuel pressure is low,
Recommended Actions
replace the fuel filters. If the fuel pressure is still
low, check the following items: fuel transfer pump, Batteries and/or Battery Cables
fuel transfer pump coupling, and fuel pressure
regulating valve. 1. Inspect the main
and battery cables power switch,
for loose battery posts,
connections and
for corrosion. If the battery cables are corroded,
Air Shutoff Valves (if applicable) remove the battery cables and clean the battery
cables. Tighten any loose connections.
1. Verify that the air shutoff valves are open.
2. Inspect the batteries.
2. Check for restrictions in the air inlet system. Refer
to the Systems Operation/Testing and Adjusting
a. Charge the batteries. Refer to Special
manual for information on the air inlet system.
Instruction, SEHS7633, “Battery Test
Procedure”.
Low Idle
b. Load test the batteries. Refer to Special
Check the low idle setting. Instruction, SEHS9249, “Use of 4C-4911
Battery Load Tester for 6, 8 and 12 Volt Lead
Accessory Equipment Acid Batteries”.
Check all accessory equipment for problems that Starting Motor Solenoid or Starting
may create excessive load on the engine. Repair
Circuit
any damaged components or replace any damaged
components.
1. Check the operation of the engine start switch.
Monitor the engine start switch on Cat ET.
i02385621
Refer to the appropriate troubleshooting test that
Engine Will Not Crank is applicable to your engine if repairs are required.
SMCS Code: 1000-038; 1901-038 2. Test the operation of the starting motor solenoid.
• Hydraulic cylinder lock Ensure that the crank enable switch is not faulty.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 50/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 51
Troubleshooting Section
• Hydraulic pump that is driven from the rear gear Oil Level
group
Inspect the engine oil level. Remove any extra oil
• Air compressor from the engine. Recheck all fluid levels.
• Other components that are driven by the engine Check for leaks in the engine oil cooler. Check for oil
in the engine coolant. If necessary, repair the engine
Hydraulic Cylinder Lock oil cooler.
Note: Drain the fuel from the cylinder head. Fuel will Check
leakagethe air the
past inlet manifold
seal forthe
rings in oil.impeller
Check for
endoilof
flow from the cylinder head into the cylinders when the turbocharger shaft. If necessary, repair the
the unit injector is removed. turbocharger.
• Bent components
i02304643
• Oil leaks
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 51/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
52 RENR5622
Troubleshooting Section
• Valve adjustment 2. Verify that the crankshaft and the camshaft drive
gears are set with the proper orientation. Refer to
the Disassembly and Assembly manual.
Recommended Actions
Air Shutoff (if applicable) Turbocharger Compressor Outlet
Pressure Sensor, “Fuel Position”, and/or
Check that both the air shutoffs are open. “FRC Fuel Limit”
Air Inlet and Exhaust System 1. Monitor the status of “Fuel Position” and “Rated
Fuel Limit” while the engine is operating under full
1. Check the air inlet system for restrictions and/or load. If “Fuel Position” equals “Rated Fuel Limit”
for leaks. and “Fuel Position” is less than “FRC Fuel Limit”,
the electronics are operating correctly. Otherwise,
a. Check for an air filter restriction. proceed to the next Step.
b. Check for derates and for alarms. 2. Verify that there are no active diagnostic codes
for the turbocharger compressor outlet pressure
c. Perform a visual inspection of the system for sensor.
restrictions and/or for leaks.
3. Monitor the status of “Turbocharger compressor
2. Check the exhaust system for restrictions. outlet pressure” and “Atmospheric Pressure” for
normal operation on the Caterpillar Electronic
3. Repair any leaks that were found. Remove Technician (ET). When the engine is not running,
any restrictions that were found. Replace any “Turbocharger compressor outlet pressure” should
damaged components that were found. be 0 kPa (0 psi).
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 52/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 53
Troubleshooting Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 53/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
54 RENR5622
Troubleshooting Section
Component Wear
Check the engine for the following problems:
Excessive valve wear, piston wear, ring wear, liner
wear, and reduced compression pressure.
Cooling System
Check for proper operation of the jacket water heater.
Repair the jacket water heater or replace the jacket
water heater. Check for an internal coolant leak into
the cylinder and/or the exhaust. Refer to the Systems
Operation/Testing and Adjusting manual for more
information.
i02416909
Table 22
Event Code
Description Conditions which Generate this Code System Response
E021 High Exhaust Temperature Derate The exhaust temperature is above the The code is active and the code is
trip point. logged.
• Air inlet and exhaust system Faulty injectors that deliver too much fuel will increase
exhaust temperatures. Connect Caterpillar Electronic
• Fuel injectors Technician (ET) in order to determine if any diagnostic
codes for the injector solenoids are present. Perform
• Aftercooler the “Injector Solenoid Test”. Observe that the injector
solenoids are being energized on Cat ET. Perform the
• Accessory equipment “Cylinder Cutout Test”. Locate the misfiring cylinder.
Refer to Troubleshooting, “Injector Solenoids”.
Recommended Actions
Aftercooler
Air Inlet and Exhaust System
Normal intake manifold pressure with high exhaust
temperature can be caused by blockage of the fins of
Check for air inlet restrictions and/or leaks. A one
the aftercooler core.
degree increase in the inlet manifold temperature will
increase the exhaust temperature by approximately
Check the aftercooler for correct operation. Check for
three degrees. Check for leaks between the exhaust
blockage in the cores of the aftercooler.
manifold and the turbocharger. Check for exhaust
restrictions. Refer to the Systems Operation/Testing
and Adjusting manual for more information on Accessory Equipment
inspecting the air inlet and exhaust system.
Check all flywheel and damper driven equipment
for proper operation. Ensure that the accessory
equipment is not lugging down the engine.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 54/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 55
Troubleshooting Section
i02119587 i01405833
• Cracked fuel supply manifold 2. Remove the fuel supply and the fuel return line
from the cylinder head.
• Leaking seal on the fuel transfer pump
3. Cap the fuel return connector and apply 700 kPa
Recommended Actions (100 psi) maximum air pressure to the fuel supply
connector. Check for fuel leakage around the unit
injectors. If leakage is present, remove the unit
Leaking Seals on the Case of the Unit injector and install a new O-ring seal.
Injector or on the Barrel of the Unit
Injector i02423656
Look for signs of damage to the seals for the unit Inlet Air Restriction
injectors. Replace any seals that are leaking.
SMCS Code: 1087-038; 1901-038
Leaking Seals on the Fuel Line Adapter
Use this procedure if the following event code is
for the Cylinder Head active.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 55/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
56 RENR5622
Troubleshooting Section
Table 23
Event Code
Description Default Conditions which Generate System Response
this Code
E272 Air Filter Restriction Warning The inlet air restriction is above the trip The code is active and the code is
point. logged.
• Air filter element Use Cat ET to monitor the status of the engine. Check
for active shutdowns due to the engine shutdown
switch. Determine the cause for the active shutdown
Recommended Actions and make any repairs necessary.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 56/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 57
Troubleshooting Section
Probable Causes If any of the above values are changing rapidly for
no apparent reason, there may be an intermittent
• Fuel position multiplier (if applicable) problem with the wiring. Refer to the diagnostic
functional test Troubleshooting, “Inspecting Electrical
• Engine speed/timing sensor(s) Connectors”.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 57/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
58 RENR5622
Troubleshooting Section
Check for an air filter restriction indicator. Replace 5. Check the fuel pressure after the fuel filter
plugged air filters and/or clean filters. Repair any while the engine is being cranked. Refer to
leaks. the Systems Operation/Testing and Adjusting
manual for the correct pressure values. If the
Throttle Signal fuel pressure is low, replace the fuel filters. If
the fuel pressure is still low, check the following
Use Cat ET in order to monitor the status of the items: fuel transfer pump, fuel transfer pump
throttle. Observe the throttle position. Verify that the coupling, and fuel pressure regulating valve. Refer
throttle position is smooth from low idle to high idle. to Systems Operation/Testing and Adjusting for
The throttle position should reach 100 percent at more information.
high idle.
i02417359
ECM Power Supply
Low Engine Oil Pressure
1. Inspect the circuit between the ECM and
the batteries. Refer to the Electrical System SMCS Code: 1300-038; 1901-038
Schematic. Inspect the wires, the connectors,
and the components in the circuit. Refer to NOTICE
Troubleshooting, “Electrical Power Supply” for Do not operate engine with low oil pressure. Engine
more information. damage will result. If measured engine oil pressure is
2. Inspect the circuit between the ECM and the low, discontinue engine operation until the problem is
corrected.
keyswitch. Refer to the Electrical System
Schematic. Inspect the wires, the connectors,
and the components in the circuit. Refer to Use this procedure in order to troubleshoot low
Troubleshooting, “Electrical Power Supply” for engine oil pressure or use this procedure if one
more information. of the following event codes is active. Refer to
Troubleshooting, “Event Code List” for information on
specific trip points for the event codes.
Fuel Supply
1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 58/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 59
Troubleshooting Section
Table 24
Event Code
Description Conditions which Generate this Code System Response
E072 Oil Level Low Mark The oil level switch opens. The code is active and the code is
logged.
E073 Oil Filter Differential Pressure The oil filter differential pressure is
High greater than the trip point.
E074 Oil Filter Differential Pressure
Very High
E100 Low Engine Oil Pressure Warning The engine oil pressure is below a map
dependent value.
• Low engine oil level Check for presence of fuel in lubricating oil. Refer
to the diagnostic procedure Troubleshooting, “Fuel
• Dirty engine oil filters Dilution of Engine Oil”.
• Crankshaft bearings
i02304726
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 59/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
60 RENR5622
Troubleshooting Section
Cold Mode Operation and Cold Cylinder Operate the engine under full load. Use Cat ET in
order to monitor the following values: turbocharger
Cutout compressor outlet pressure, fuel position, rated fuel
position, and Fuel Ratio Control (FRC). The fuel
Use the Caterpillar Electronic Technician (ET) in
position should equal the rated fuel position. The
y that the engine has exited cold mode.
order tocold
During verifmode, fuel injection timing is modified. FRC fuel position should be greater than the rated
fuel position.
When the engine is in cold mode, the cold cylinder
cutout strategy may be active. Cold mode cylinder
If any of the above values are changing rapidly for
cutouts may cause variations in vibration and
no apparent reason, there may be an intermittent
available power. This is normal operation.
problem with the wiring. Refer to the diagnostic
functional test Troubleshooting, “Inspecting Electrical
Derate Mode Connectors”.
The throttle
high idle. position should reach 100 percent at If you have replaced the ECM, check the read/change
system configuration parameters. Verify that the
parameters match the information on the engine
Electrical Connector information plate. Verify that the correct flash file has
been installed.
Check for the correct installation of the ECM
connector(s) J1/P1 and/or J2/P2. Check for
Fuel Supply
correct installation of the applicable fuel Injector
connectors. Refer to the diagnostic functional test
Check the fuel pressure after the fuel filter while
Troubleshooting, “Inspecting Electrical Connectors”.
the engine is being cranked. Refer to the Systems
Operation/Testing and Adjusting manual for the
Injector correct pressure values. If the fuel pressure is low,
replace the fuel filters. If the fuel pressure is still low,
Use Cat ET to determine if any active diagnostic check the following items: fuel transfer pump, fuel
codes are present. Check that the injector trim codes transfer pump coupling, and fuel pressure regulating
have been entered. Use Cat ET to determine if any valve. Refer to the Systems Operation/Testing and
logged diagnostic codes are present. Perform the Adjusting manual for more information.
“Injector Solenoid Test”. Observe that the solenoids
for the injectors are being energized on Cat ET.
Air Shutoff Valve (if applicable)
Perform the “Cylinder Cutout Test”. Locate the
misfiring cylinder. Refer to the diagnostic functional
Check that both of the air shutoffs are open.
test Troubleshooting, “Injector Solenoids”.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 60/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 61
Troubleshooting Section
Check the crankshaft and/or crankshaft bearings. Test”. Locate the misfiring cylinder. Refer to the
diagnostic functional test Troubleshooting, “Injector
Check the components for excessive wear. Solenoids”.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 61/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
62 RENR5622
Troubleshooting Section
Fuel Supply
i02421030
1. Check the fuel lines for the following problems:
Poor Fuel Consumption restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
SMCS Code: 1000-038; 1901-038 lines and/or replace the lines.
• Engine speed/timing sensor(s) 3. Prime the fuel system if any of the following
procedures have been performed:
• Electrical connectors
• Replacement of the fuel filters
• Injector • Service on the low pressure fuel supply circuit
• Fuel supply
• Replacement of unit injectors
• Air inlet restrictions
Refer to the Operation and Maintenance Manual
• Exhaust restrictions for the correct procedure.
• Accessory equipment Note: A sight glass in the fuel supply line is helpful in
diagnosing air in the fuel.
Recommended Actions
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Engine Speed/Timing Sensor(s) Maintenance Manual for information on improving
Check the calibration of the engine speed/timing the characteristics of the fuel during cold weather
operation.
sensor if a CID-FMI 261-13 Engine Timing calibration
required diagnostic code is active. Refer to the
calibration procedure Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 62/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 63
Troubleshooting Section
5. Check the fuel pressure after the fuel filter Recommended Actions
while the engine is being cranked. Refer to
the Systems Operation/Testing and Adjusting Rocker Arm
manual for the correct pressure values. If the
fuel pressure is low, replace the fuel filters. If Check for proper installation of the rocker arm
the fuel pressure is still low, check the following adjustment screw locknut. If the rocker arm
items: fuel transfer pump, fuel transfer pump adjustment screw locknut is loose, adjust the valve
coupling, and fuel pressure regulating valve. Refer lash.
to Systems Operation/Testing and Adjusting for
more information. Check the rocker arms for signs of wear. If there is
too much wear, install new parts or rocker arms.
Air inlet Restrictions Adjust the valve lash.
Inspect the engine air cleaner. Replace plugged air Not Enough Lubrication
filters and/or clean the filters. Check the air inlet
systems for restrictions and for leaks. Check the lubrication in the valve compartment.
Check for sufficient lubrication between the injector
Exhaust Restrictions tappet and the rocker arm buttons.
Check the exhaust systems for restrictions and for Worn Bridges for Valves
leaks.
Check the bridges for signs of wear. Adjust the
Accessory Equipment bridges and/or replace the bridges. If there is too
much wear, install new parts. Adjust the valve lash.
Check attached accessory equipment. Ensure that
the accessory equipment is not lugging down the Worn Pushrods
engine.
Inspect the pushrods for signs of wear. If there is too
i02304819
much wear, install new pushrods. Adjust the valve
lash.
Too Much Valve Lash
Worn Valve Lifters
SMCS Code: 1000-038; 1901-038
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 63/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
64 RENR5622
Troubleshooting Section
Check the valve seats for signs of wear. If there is Valve Rotocoil or Spring Lock
too much wear, install new valve seats. Adjust the Is Free
valve lash.
SMCS Code: 1109-038
i02304874
Probable Causes
Too Much Vibration
• Cracked inlet valve rotocoil
SMCS Code: 1000-038; 1901-038
• Broken spring locks
Probable Causes
• Broken valve spring(s)
• Vibration damper
Recommended Actions
• Loose engine supports
• Fan blade Valve Rotocoil
Fan blade
Check the fan blade for damage. Ensure that the fan
blade is balanced.
Misfiring cylinder
Check
Cutout for a misfiring
Test. Refer to cylinder. Perform
the diagnostic the Cylinder
functional test
Troubleshooting, “Injector Solenoids”.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 64/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 65
Troubleshooting Section
Diagnostic Functional
Tests
i02408931
Table 25
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 65/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
66 RENR5622
Troubleshooting Section
MID 0036 - CID 0829 - FMI 04 Rear The ECM detects signal voltage that is
Aftercool Temperature short to ground below normal for one second.
The ECM has been powered for three
seconds.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 66/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 67
Troubleshooting Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 67/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
68 RENR5622
Troubleshooting Section
g01203777
Illustration 14
Typical schematic
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 68/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 69
Troubleshooting Section
g01208832 g01208831
Illustration 15 Illustration 16
Front and Left view Rear and Right view
(1) Turbocharger compressor outlet pressure sensor (boost) (9) Aftercooler temperature sensor (rear)
(2) Aftercooler temperature sensor (front) (10) Crankcase pressure sensor
(3) Right turbocharger compressor inlet pressure sensor
(4) Coolant temperature sensor
(5) Left turbocharger compressor inlet pressure sensor
(6) Unfiltered engine oil pressure sensor
(7) Filtered engine oil pressure sensor
(8) Atmospheric pressure sensor
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 69/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
70 RENR5622
Troubleshooting Section
g01203763 g01203760
Illustration 17 Illustration 18
P1 ECM connector P2 ECM connector
(P1-1) Aftercooler temperature sensor (front) (P2-36) Turbocharger outlet pressure sensor
(P1-2) 5 V sensor supply (P2-37) Atmospheric sensor
(P1-3) Sensor return (P2-38) Left turbocharger inlet pressure sensor
(P1-6) Aftercooler temperature sensor (rear) (P2-39) Right turbocharger inlet pressure sensor
(P1-7) Coolant temperature sensor (P2-46) Crankcase pressure sensor
(P1-16) Filtered engine oil pressure sensor
(P1-17) Unfiltered engine oil pressure sensor
(P1-18) 5 V sensor supply
(P1-35) Sensor return
g01094844
Illustration 19
Sensor connector
(Pin A) 5 V sensor supply
(Pin B) Sensor return
(Pin C) Signal
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 70/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 71
Troubleshooting Section
C. Monitor the diagnostic codes on Cat ET. Check • OK – No intermittent problems were found. The
and record any diagnostic codes. harness and connectors appear to be OK. If a
diagnostic code is still active, proceed to Test
Note: Wait at least 30 seconds in order for the Step 1 and continue to troubleshoot the active
diagnostic codes to become active. diagnostic code.
D. Determine if a diagnostic code has occurred • Not OK – At least one intermittent problem was
several times. indicated.
Note: A diagnostic code that is logged several Repair: Repair the harness or the connector. Refer
times is an indication of an intermittent problem. to the diagnostic functional test Troubleshooting,
Most intermittent problems are the result of a bad “Inspecting Electrical Connectors”. Verify that the
connection between a socket and a pin in a connector repair eliminates the problem.
or a bad connection between a wire and a terminal.
STOP.
E. Determine if the problem is active and related to
one of the following diagnostic codes: Test Step 3. Check the Supply Voltage at
the Sensor Connector
• 03
A. Remove electrical power from the ECM.
• 04
B. Disconnect the suspect sensor(s) at the sensor
Expected Result: connector:
A diagnostic code has occurred several times. C. Restore electrical power to the ECM.
No intermittent problems were detected during the E. Monitor the diagnostic codes on Cat ET. Check
“Wiggle Test”. for an active 04 diagnostic code for the suspect
sensor.
F. Remove electrical power from the ECM. Repair: Temporarily connect a new sensor to the
harness, but do not install the new sensor in the
Expected Result: engine. Verify that there are no active diagnostic
codes for the sensor. If there are no active
A 04 diagnostic code is now active for the suspect diagnostic codes for the sensor, permanently
sensor(s). install the new sensor. Clear any logged diagnostic
codes.
Results:
STOP.
• OK – A 03 diagnostic code was active before
creating the short at the sensor connector. A 04 • Not OK – A 04 diagnostic code is still active for the
diagnostic code became active after creating the suspect sensor. Leave the sensor disconnected.
short at the sensor connector. The harness and The problem may be in the harness or with the
the ECM are OK. There may be a problem with ECM. Proceed to Test Step 6.
the sensor.
Test Step 6. Check the Operation of the
Repair: Temporarily connect a new sensor to the ECM
harness, but do not install the new sensor in the
engine. Verify that there are no active diagnostic A. Remove electrical power from the ECM.
codes for the sensor. If there are no active
diagnostic codes for the sensor, permanently B. Check the operation of the ECM by creating an
install the new sensor. Clear any logged diagnostic open at the ECM.
codes.
a. Remove the signal wire for the suspect sensor
STOP. from the P1 or P2 ECM connector. Refer to
Illustration 14 for terminal locations.
• Not OK – A 03 diagnostic code is still active for
the suspect sensor(s). The problem may be in the b. Install a jumper wire with Deutsch sockets on
harness or with the ECM. Proceed to Test Step 6. each end into the socket for the signal wire of
the suspect sensor.
Test Step 5. Create an Open at the
Suspect Sensor Connector c. Reconnect the ECM connectors.
A. Remove electrical power from the ECM. d. Restore electrical power to the ECM.
B. Disconnect the sensor connector of the suspect e. Monitor the “Active Diagnostic Code” screen on
sensor(s) with the active 04 diagnostic code. Cat ET. Wait at least 30 seconds for activation
of the code.
C. Restore electrical power to the ECM.
An open circuit diagnostic code 03 should be
D. Monitor the diagnostic codes on Cat ET. Check active for the suspect sensor.
for an active 03 diagnostic code for the suspect
sensor. C. Check the operation of the ECM by creating a
short at the ECM.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active. a. Install a wire jumper between the wire jumper
for the signal wire for the suspect sensor and
E. Remove electrical power from the ECM. engine ground.
• OK – A 04 diagnostic code was active before c. Remove the wire jumper. Reconnect all wires
disconnecting the sensor. A 03 diagnostic code and connectors.
became active after disconnecting the sensor. The
harness and the ECM are OK. There may be a
problem with the sensor.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 72/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 73
Troubleshooting Section
A 03 diagnostic code is active when the sensor • OK – The supply voltage is 5.0 ± 0.2 VDC. The
signal wire is removed from the ECM connector. A supply voltage at the ECM is correct. There is a
04 diagnostic code is active when the signal wire is problem in the wiring between the ECM and the
connected to engine ground. sensor connector. Check the supply wires and the
return wire for an open circuit.
Results:
Repair: Repair the connectors or wiring and/or
• OK – The ECM is operating properly. The problem replace the connectors or wiring.
is in the wiring between the ECM and the connector
for the rail. STOP.
Repair: If the code is active for more than one • Not OK – The supply voltage is not 5.0 ± 0.2 VDC.
sensor, the problem is most likely in the return wire The voltage at the ECM is not correct.
for the sensor. Repair the return wire for the sensor
or replace the harness. Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”.
If the code is only active for one sensor, the Verify that the problem is resolved.
problem is most likely in the signal wire for the
sensor. Repair the signal wire for the sensor. STOP.
STOP.
i02409119
Expected Result:
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 73/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
74 RENR5622
Troubleshooting Section
Table 26
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 74/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 75
Troubleshooting Section
g01203833
Illustration 20
Schematic
Expected Result:
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 75/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
76 RENR5622
Troubleshooting Section
• Not OK – The connectors and/or wiring are not C. Measure the resistance at the connectors of the
OK. other control modules.
Test Step 2. Check for Shorts in the Repair: If the problem is intermittent, perform
Harness the diagnostic functional test Troubleshooting,
“Inspecting Electrical Connectors”.
A. Disconnect ECM connector J1/P1 at the engine
ECM. STOP.
B. Disconnect all control modules from the Cat Data • Not OK – The resistance measurement does not
Link. indicate a short circuit. There is an open circuit in
the harness or connectors.
C. Disconnect Cat ET from the service tool connector.
Repair: Repair the connectors or wiring and/or
D. Measure the resistance from P1-8 to every replace the connectors or wiring.
terminal on ECM connectors P1 and P2.
STOP.
E. Measure the resistance from P1-8 to the chassis
ground.
i02409173
Results:
STOP.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 76/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 77
Troubleshooting Section
Table 27
Event Code
Description Default Conditions which Generate System Response
this Code
E035 Loss of Coolant Flow Warning The coolant flow switch opens. The code is active and the code is
logged.
g01208730
Illustration 22
Right side view
(1) Coolant flow switch
g01203867
Illustration 23
Schematic
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 77/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
78 RENR5622
Troubleshooting Section
g01147985 g01147988
Illustration 24 Illustration 25
P1 ECM connector P2 ECM connector
(P1-30) Coolant flow (P2-54) Digital return
Expected Result:
Results:
STOP.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 78/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 79
Troubleshooting Section
E. Check the harness and wiring for abrasions and • Not OK – Cat ET does not indicate “NO FLOW”
for pinch points from the sensors back to the ECM. while the engine is not running. Cat ET does not
indicate “FLOW” while the engine is running. Cat
Expected Result: ET does not indicate the correct status of the
coolant flow switch. Proceed to Test Step 4.
All connectors, pins, and sockets are completely
inserted and coupled. The harness and wiring are Test Step 4. Create a Short Circuit at the
free of corrosion, of abrasion, and of pinch points. Connector of the Coolant Flow Switch
All connections and grounds are tight and free of
corrosion. A. Disconnect the connector for the coolant flow
switch.
Results:
B. Use a suitable piece of wire to short terminal 1
• OK – The har ness and wiring are OK. Proceed (coolant flow switch) to terminal 2 (engine ground).
to Test Step 3.
C. Turn the keyswitch to the ON position.
• Not OK – There is a problem in the connectors
and/or wiring. D. Observe the status of “Engine Coolant Flow” on
Cat ET.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of E. Turn the keyswitch to the OFF position.
the seals are properly in place and ensure that the
connectors are completely coupled. Expected Result:
Verify that the repair eliminates the problem. The status indicates “Flow” with the jumper wire in
place.
STOP.
Results:
Test Step 3. Check the Status of the
Coolant Flow on Caterpillar Electronic • OK – The ECM and the wiring are operating
Technician (ET) correctly. Proceed to Test Step 5.
A. Restore electrical power to the engine ECM. • Not OK – The status indicates “NO FLOW”.
Proceed to Test Step 6.
B. Connect Cat ET to the service tool connector.
Test Step 5. Check the Coolant Flow C. Reconnect the J1/P1 ECM connector.
Switch
D. Use a suitable piece of wire to short the wire
jumper in P1-30 to engine ground.
D. Measure continuity between termnal 1 and Repair: There is an open in the wire between
terminal 2 with the switch in the closed position. termnal 1 and the ECM and/or there is an open
in the digital return wire between termnal 2 and
Expected Result: P2-54. Repair the wire.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 80/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 81
Troubleshooting Section
Table 28
a difficultyaccessories.
electrical in starting isEngine
not accompanied
shutdownsby loss
that areof
accompanied by a loss of other electrical accessories
indicate a problem in the keyswitch. This does not
indicate a problem in the wiring at the ECM. Verify
that there are no problems with the starting system or
with the charging system before you use this test.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 81/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
82 RENR5622
Troubleshooting Section
g01203933
Illustration 26
Typical schematic
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 82/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 83
Troubleshooting Section
Results:
STOP.
Expected Result:
Results:
g01203934
Illustration 27 • OK – The voltage is 24 ± 3 VDC. Proceed to Test
P1 ECM connector Step 3.
(P1-52) +Battery
(P1-53) +Battery • Not OK – The voltage is not 24 ± 3 VDC.
(P1-63) − Battery
(P1-65) − Battery
Repair: There is a problem with the batteries
(P1-70) Keyswitch
or the charging system. Refer to Systems
Test Step 1. Inspect Electrical Connectors Operation/Testing and Adjusting for information on
the charging system.
and Wiring
STOP.
A. Remove electrical power from the ECM.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 83/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
84 RENR5622
Troubleshooting Section
Test Point
STOP.
Terminal for wire 112-PU
Test Step 4. Check the Voltage from the Wire 109-OR
Keyswitch to the Main Power Relay
Wire 308-YL
A. Turn the keyswitch to the OFF position.
D. Turn the keyswitch to the OFF position.
B. Remove the wire from the terminal R of the
keyswitch. Expected Result:
C. Turn the keyswitch to the ON position. The voltage measures 24 ± 3 VDC between each of
the test points and engine ground.
D. Measure the voltage on terminal B of the
keyswitch to engine ground. Results:
E. Measure the voltage on terminal R of the • OK – The voltage measures 24 ± 3 VDC between
keyswitch to engine ground. each of the test points and engine ground.
F. Turn the keyswitch to the OFF position. Repair: Verify that the “VIMS Breaker” is not
tripped. Repair the wiring and/or connectors
Expected Result: between the main power relay and the “VIMS
Breaker”. Repair the wiring and/or connectors
Voltage is present on terminal B and terminal R at between the “VIMS Breaker” and the ECM.
the keyswitch.
STOP.
Results:
• Not OK – Voltage is not present on terminal B at Repair: If voltage is present at the other two
the keyswitch. test points, check the wire 200-BK for continuity
between engine ground and the main power relay.
Repair: If voltage is not present on terminal B, If wire 200-BK is OK, replace the main power relay.
repair the wire between the +Battery and the
keyswitch. Verify that the breaker for the keyswitch STOP.
is not tripped. Verify that the problem is eliminated.
• Not OK – The voltage does not measure 24 ± 3
STOP. VDC between wire 109-OR and engine ground.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 84/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 85
Troubleshooting Section
STOP.
STOP.
i02409475
Table 30
Event Code
Description Conditions which Generate this Code System Response
E072 Oil Level Low Mark The oil level switch opens. The code is active and the code is
logged.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 85/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
86 RENR5622
Troubleshooting Section
Illustration 28 g01208732
g01203953
Illustration 29
Schematic
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 86/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 87
Troubleshooting Section
Expected Result:
Results:
g01203954
Illustration 30
P1 ECM connector • OK – The harness and wiring are OK. Proceed
(P1-22) Low oil level to Test Step 2.
STOP.
Expected Result:
Results:
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 87/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
88 RENR5622
Troubleshooting Section
A. Connect Cat ET to the service tool connector. Repair: Temporarily replace the switch. Verify
that a new switch solves the problem before you
B. Turn the keyswitch to the ON position. permanently install the new switch.
• OK – The “Engine Oil Level” reads “OK”. Test Step 5. Short the Input Wires of
the Low Oil Level Switch at the ECM
Repair: The switch signal is correct. Connector
STOP. A. Disconnect ECM connector P1.
• Not OK – The “Engine Oil Level” does not read B. Remove the wire from P1-22 (low oil level). Install
“OK”. The switch signal is not correct. Proceed to a wire jumper with a socket on one end into P1-29.
Test Step 4.
C. Remove the wire from P2-66 (digital return). Install
Test Step 4. Short the Wires at the Low a wire jumper with a socket on one end into P2-20.
Oil Level Switch
D. Connect a wire jumper between the wire jumpers
A. Disconnect the connector for the low oil level in P1-22 and P2-66.
switch.
E. Reconnect all connectors.
B. Use a wire to short terminal terminal 1 to terminal
2. Install the wire jumper on the harness side of F. Turn the keyswitch to the ON position.
the connector.
Note: Additional diagnostic codes will be generated
C. Turn the keyswitch to the ON position. because the digital return will no longer be connected
to the other sensors and switches. Ignore the codes
D. Observe the status of the “Engine Oil Level” on and clear the codes when you complete this test.
Cat ET.
G. Observe the status of the “Engine Oil Level” on
E. Remove the wire short. Cat ET.
F. Observe the status of the “Engine Oil Level” on H. Remove the wire short.
Cat ET.
I. Reconnect all connectors.
G. Turn the keyswitch to the OFF position.
J. Observe the status of the “Engine Oil Level” on
Expected Result: Cat ET.
Cat ET indicates “OK” when the wire short is K. Turn the keyswitch to the OFF position.
installed. Cat ET indicates “LOW” when the wire short
is removed. L. Reconnect all connectors.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 88/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 89
Troubleshooting Section
Expected Result:
Results:
• OK – Cat ET indicates that the “Engine Oil Level”
is “OK” when the wire short is installed. Cat ET
indicates that the “Engine Oil Level” is “LOW” when
the wire short is removed. The problem is in the
harness between the ECM and the low oil level
switch.
STOP.
STOP.
i02409564
Table 31
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 89/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
90 RENR5622
Troubleshooting Section
g01152043
Illustration 32
Schematic
P2 ECM connector
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 90/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 91
Troubleshooting Section
Results:
STOP.
All connectors, pins, and sockets are completely D. Select the override for the engine oil renewal
coupled and/or inserted. The harness and wiring are solenoid on Cat ET.
free of corrosion, of abrasion, and of pinch points.
E. Set the override for the engine oil renewal solenoid
to 100 percent.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 91/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
92 RENR5622
Troubleshooting Section
F. Measure the voltage between terminal 1 and Repair: Replace the ECM. Refer to
terminal 2 at the solenoid connector. Troubleshooting, “Replacing the ECM”.
Expected Result:
Results:
STOP.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 92/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 93
Troubleshooting Section
Table 32
Event Code
Description Conditions which Generate this Code System Response
MID 0036 - CID 0190 - FMI 08 Engine The engine speed is greater than zero The engine speed is set to zero rpm.
Speed signal abnormal rpm and the pattern from the timing ring The code is active.
is incorrect for five seconds. The code is logged if the pattern from
the timing ring returns for five seconds.
The
signalengine
to thespeed/timing
ECM as eachsensor generates
tooth passes theasensor.
pulse
The ECM counts the pulses in order to determine the
engine rpm. The ECM memorizes the pattern of the
pulses. The ECM compares that pattern to a standard
pattern in order to determine the crankshaft position.
The ECM uses this information to determine the No.
1 cylinder. The ECM then triggers each fuel injector to
fire in the correct firing order and at the correct time.
The actual timing and duration of each injection is
determined by the ECM. The ECM uses engine rpm Illustration 34
g01208740
and engine load to determine the timing and duration
Left side view
of injection. The loss of the signal from the engine
(1) Engine speed/timing sensor
speed/timing sensor generates a diagnostic code.
The loss of the signal from the engine speed/timing
sensor triggers the termination of the signals to the
fuel injectors by the ECM.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 93/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
94 RENR5622
Troubleshooting Section
g01204148
Illustration 35
Schematic
Expected Result:
Results:
g01156100
• Not OK – There is a problem with the connectors
Illustration 36 and/or wiring.
P1 ECM connector
(P1-5) Digital return Repair: Repair the connectors or wiring and/or
(P1-33) Engine speed/timing signal replace the connectors or wiring. Ensure that all of
(P1-40) Engine timing calibration - the seals are properly in place and ensure that the
(P1-41) Engine timing calibration +
connectors are completely coupled.
(P1-43) +12 V supply
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 94/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 95
Troubleshooting Section
Test Step 2. Check for a “LOGGED” D. Measure the voltage between the sensor signal
Diagnostic Code wire and terminal B of the sensor connector. Crank
the engine and measure the voltage between the
A. Connect Caterpillar Electronic Technician (ET) to sensor signal wire and terminal B.
the service tool connector.
E. Turn the keyswitch to the OFF position.
B. Turn the keyswitch to the ON position.
F. Reconnect the signal wire.
C. Check the diagnostic codes on Cat ET.
Expected Result:
Expected Result:
The voltage measures less than 3 VDC or more than
Cat ET indicates that a 190-08 diagnostic code has 9 VDC when the keyswitch is in the ON position
recently been logged. and the engine is not cranking. While the engine is
cranking, the voltage is between 2.0 VDC and 7.0
Results: VDC.
• OK – The 190-08 diagnostic code is logged. Note: The voltage output is determined by the
Proceed to Test Step 3. presence or the absence of a tooth on the timing gear.
Repair: The problem is no longer present. If the • OK – The engine speed/timing sensor is producing
problem is intermittent, refer to Troubleshooting, the correct output signal. Proceed to Test Step 5.
“Inspecting Electrical Connectors”.
• Not OK – The engine speed/timing sensor is not
STOP. producing the correct output signal.
Test Step 3. Check the Supply Voltage to Repair: Replace the engine speed/timing sensor.
the Sensor Calibrate the sensor. Perform the calibration
procedure Troubleshooting, “Engine Speed/Timing
A. Disconnect the connector for the engine Sensor - Calibrate”.
speed/timing sensor.
STOP.
B. Turn the keyswitch to the ON position.
Test Step 5. Check the Signal Voltage at
C. Measure the voltage between terminal A and the ECM
terminal B at the sensor connector.
A. Turn the keyswitch to the OFF position.
Expected Result:
B. Disconnect ECM connector J1/P1.
The supply voltage is 12 ± 1.0 VDC.
C. Remove wire 999-WH from ECM connector P1-33.
Results:
D. Reconnect ECM connector J1/P1.
• OK – The supply voltage is 12 ± 1.0 VDC. Proceed
to Test Step 4. E. Turn the keyswitch to the ON position.
• Not OK – The supply voltage is not 12 ± 1.0 VDC. F. Measure the signal voltage between the signal
Proceed to Test Step 6. wire 999-WH and engine ground.
Test Step 4. Check the Signal Voltage at G. Crank the engine and measure the signal voltage
the Sensor between the signal wire 999-WH and engine
ground.
A. Turn the keyswitch to the OFF position.
H. Turn the keyswitch to the OFF position.
B. Remove the wire from terminal C of the sensor
connector. I. Replace all wires. Reconnect ECM connector
J1/P1.
C. Turn the keyswitch to the ON position.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 95/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
96 RENR5622
Troubleshooting Section
The voltage measures less than 3 VDC or more than • OK – The supply voltage is 12 ± 1.0 VDC. There is
9 VDC when the keyswitch is in the ON position an open circuit or a short circuit between the ECM
and the engine is not cranking. While the engine is and the connector for the engine speed/timing
cranking, the voltage is between 2.0 VDC and 7.0 sensor.
VDC.
Repair: Repair the connectors and/or wiring or
Note: The voltage signal is generated by the replace the connectors and/or wiring.
presence or the absence of a tooth on the timing
gear. STOP.
STOP.
i02409847
• Not OK – There is a problem in the engine Ether Injection System
speed/timing circuit.
SMCS Code: 1456-038
Repair: The problem is between the ECM and the
engine speed/timing sensor. Repair the connectors System Operation Description:
and/or wiring or replace the connectors and/or
wiring. Use this procedure if a problem is suspected with the
ether system or if any one of the diagnostic codes in
STOP. Table 33 is active or easily repeated.
Test Step 6. Check the Supply Voltage
for the Engine Speed/Timing Sensor at
the ECM
A. Turn the keyswitch to the OFF position.
Expected Result:
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 96/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 97
Troubleshooting Section
Table 33
MID 0036 - CID 0546 - FMI 06 Ether The ECM detects a short circuit to the
Hold Relay short to +batt +Battery at the output to the ether hold
relay.
The ECM has been powered for at least
two seconds.
When the engine is in AUTO mode the engine The ether start relay initially energizes the ether
uses an ether system to improve starting in cold solenoid for approximately two seconds. After two
temperatures. The duration of the ether cycle is seconds, the ether hold relay energizes and the
based on the engine coolant temperature. The ether start relay de-energizes. The voltage from the
Electronic Control Module (ECM), which controls the ether hold relay to the ether solenoid is less than
ether system uses the engine coolant temperature battery voltage because of the voltage drop over the
sensor to detect the engine temperature. The resistance that is in the resistor and diode assembly.
ECM determines if ether should be injected by The initial higher voltage is needed to actuate the
monitoring the actual engine rpm and the engine ether solenoid. The lower voltage signal is then used
coolant temperature. The ECM will activate the ether to hold the ether solenoid valve open. The solenoid
solenoid if the engine coolant temperature is below will be damaged if full battery voltage is applied
a set temperature and engine rpm is below a certain continuously.
level. The ether will activate for a minimum of 15
seconds at 30 °C (86 °F) up to a maximum of 130 Two circuits from the ECM are used to control the
seconds at − 50 °C (−58 °F). The automatic ether ether cycle. The device drivers in the first circuit
injection system is disabled whenever the engine rpm provide a +Battery voltage to the coil of the ether
exceeds 400 rpm or the engine coolant temperature start relay and a return path to the ECM from the coil
exceeds 30 °C (86 °F). of the ether start relay. The ECM monitors current
flow at two places in the circuit in order to determine
The ether injection system can also be operated in if there is a problem in the circuit. The ECM monitors
manual mode. The ether system is switched into current flow on the device driver to the coil of the
manual mode whenever the starting aid switch is ether start relay and the ECM monitors current flow
depressed. Manual mode also allows ether to be on the device driver from the coil of the ether start
injected whenever the coolant temperature is less relay. If current is below a threshold on either device
than 30 °C (86 °F) and the engine rpm is greater driver in the circuit, the ECM will generate a 545-05
than 50 rpm. Ether is injected in manual mode if diagnostic code. If current is above a threshold
the starting aid switch is depressed and the coolant on either device driver in the circuit, the ECM will
temperature is below the maximum limit. generate a 545-06 diagnostic code. If a 545-06
diagnostic code is generated, the ECM will latch both
device drivers open for overcurrent protection.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 97/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
98 RENR5622
Troubleshooting Section
g01204307
Illustration 37
Typical schematic
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 98/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 99
Troubleshooting Section
Illustration 38 g01149844
Terminal locations for the ether start relay and for the ether hold
relay
g01204311
Illustration 40
P2 ECM connector
(P2-10) Ether hold relay
(P2-20) Ether request
(P2-31) Ether start relay
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 99/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
100 RENR5622
Troubleshooting Section
• OK – The harness and wiring are OK. Proceed The parameter for the starting aid switch displays
to Test Step 2. “ON” while the starting aid switch is toggled. The
parameter for the starting aid switch displays “OFF”
• Not OK – There is a problem in the connectors when the starting aid switch is released. An active
and/or wiring. diagnostic code is present or a logged diagnostic
code is present.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of Results:
the seals are properly in place and ensure that the
connectors are completely coupled. • OK - Active Code – The parameter for the starting
aid switch displays “ON” while the starting aid
Verify that the repair eliminates the problem. switch is toggled. The parameter for the starting aid
switch displays “OFF” when the starting aid switch
STOP. is released. Active diagnostics are displayed. Make
a note of the active diagnostic code. Proceed to
Test Step 2. Check the Ether Canisters Test Step 4.
A. Turn the keyswitch to the OFF position. • OK - Logged Code – The parameter for the starting
aid switch displays “ON” while the starting aid
B. Remove the ether canister(s) from the ether switch is toggled. The parameter for the starting aid
solenoid(s). Verify that the ether canister is full. switch displays “OFF” when the starting aid switch
is released. Logged diagnostics are displayed.
Expected Result:
Repair: Check for an intermittent short or for
The ether canister is full. an open in the wiring or in the connectors.
Refer to Troubleshooting, “Inspecting Electrical
Results: Connectors”. Repair any suspect connectors or
wiring and/or replace the connectors or wiring.
• OK – The ether canister is full. Proceed to Test Verify that the system is operating correctly.
Step 3. Replace the ether canister on the ether solenoid.
Repair: Replace the empty ether canister with • OK - No Codes – The parameter for the starting
a full ether canister. Verify that the system is aid switch displays “ON” while the starting aid
operating correctly. switch is toggled. The parameter for the starting
aid switch displays “OFF” when the starting aid
STOP. switch is released. No diagnostics are logged or
active. The ether system is not injecting ether.
Test Step 3. Check for Active Diagnostic Proceed to Test Step 8.
Codes
• Not OK – The parameter for the starting aid switch
Note: Remove the ether canister(s) from the ether does not display “ON” while the starting aid switch
solenoid(s) before proceeding with the following test is toggled. The parameter for the starting aid
steps. switch does not display “OFF” when the starting
aid switch is released. The starting aid switch is not
A. Connect Caterpillar Electronic Technician (ET) to functioning correctly. Proceed to Test Step 12.
the cab service tool connector. Start Cat ET.
Test Step 4. Switch the Relays in order to
B. Turn the keyswitch to the ON position. Isolate the Problem
C. Toggle the starting aid switch. Observe the A. Turn the keyswitch to the OFF position.
parameter for the starting aid switch on Cat ET.
B. Remove the ether start relay and the ether hold
D. Determine if CID-FMI 545-05, 545-06, 546-05 or relay. Replace the ether start relay in the base for
546-06 is active or logged. the ether hold relay. Replace the ether hold relay
in the base for the ether start relay.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 100/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 101
Troubleshooting Section
D. Select the “Diagnostic Tests” on Cat ET. E. Select the “Override Parameters” screen on Cat
ET.
NOTICE
Do not allow the ether injection system to be on for F. Activate the ether override.
more than two minutes. Damage to the ether solenoid
G. Monitor the active diagnostic code screen on Cat
may occur.
ET. Check and record any active diagnostic codes.
E. Select the “Override Parameters” screen on Cat Note: Wait at least 30 seconds in order for the
ET. diagnostic codes to become active.
The 05 or 06 diagnostic code is now active for the Repair: The ECM detected the short circuit at
other relay. the relay connector. The problem must be in the
connector for the suspect relay or the problem
Results: must be in the relay assembly.
Test Step 5. Create a Short at the Note: Wait at least 30 seconds in order for the
Connector for the Suspect Relay diagnostic codes to become active.
A. Turn the keyswitch to the OFF position. E. Disable the ether override.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 101/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
102 RENR5622
Troubleshooting Section
Repair: The ECM detected the open circuit at b. Turn the keyswitch to the ON position.
the relay connector. The problem must be in the
connector for the suspect relay or the problem c. Select the “Diagnostic Tests” on Cat ET.
must be in the relay assembly.
NOTICE
STOP.
Do not allow the ether injection system to be on for
more than two minutes. Damage to the ether solenoid
• Not OK – The 06 diagnostic code is still active for
the suspect relay. Proceed to Test Step 7.
may occur.
Test Step 7. Test the Operation of the d. Select the “Override Parameters” screen on
ECM Cat ET.
A. Turn the keyswitch to the OFF position. e. Activate the ether override.
B. Fabricate jumper wires that can be used to replace f. Monitor the “Active Diagnostic Code” screen
the wire(s) in the ECM connector for the suspect on Cat ET.
relay. Crimp a connector socket to one end of the
jumper wires. Check the suspect relay for an active 06
diagnostic code.
C. Disconnect the appropriate ECM connector for
the suspect relay. Note: Wait at least 30 seconds so that any codes
may become active.
D. Remove the wire(s) for the suspect relay from the
ECM connector. g. Disable the ether override.
E. Install the jumper wire(s) into the terminal h. Turn the keyswitch to the OFF position.
location(s) for the suspect relay at the ECM
connector. I. Remove the jumper wire. Return all wiring to the
original configuration.
F. Connect the ECM connectors.
Expected Result:
G. Check the operation of the ECM by creating
an open at the ECM: A 05 diagnostic code is active when the wires or
wire from the suspect relay are open at the ECM
a. Hold the loose end of the jumper wire away connector. A 06 diagnostic code is active if the wires
from any components in order to create an or wire from the suspect relay are shorted at the
open circuit condition. ECM connector.
c. Monitor the “Active Diagnostic Code” screen • OK – A 05 diagnostic code is active when the
on Cat ET. wires or wire from the suspect relay are open at
the ECM connector. A 06 diagnostic code is active
Check the suspect relay for an active 05 when the wires or wire from the suspect relay are
diagnostic code. shorted at the ECM connector.
Note: Wait at least 30 seconds so that any codes Repair: The ECM is operating properly.
may become active.
If the suspect relay is the ether start relay, the
d. Turn the keyswitch to the OFF position. problem is in the harness wiring between the ECM
and the connector for the relay. Repair the wires
H. Check the operation of the ECM by creating a or wire.
short circuit at the ECM:
If the suspect relay is the ether hold relay, the
a. If the suspect relay is the ether start relay, short problem is in the harness wiring between the ECM
the jumpers for the return wire and the output and the connector for the relay or in the harness
wire together. wiring between the battery and the ether hold relay.
Repair the wire.
If the suspect relay is the ether hold relay, short
the jumper for the return wire to the +Battery. STOP.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 102/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 103
Troubleshooting Section
• Not OK – One of the following conditions exists: • Not OK - 24 VDC – The voltage did not measure
The 05 diagnostic code is not active when the 24 ± 3 VDC for the first two seconds of injection.
wires or wire from the suspect relay are open at Verify that wire 200-BK has continuity to ground.
the ECM connector. The 06 diagnostic code is not If wire 200-BK has continuity to ground, proceed
active when the wires or wire from the suspect to test step 9.
relay are shorted at the ECM connector.
• Not OK - 3 VDC – The voltage is approximately
Repair: Replace the ECM. Refer to 24 ± 3 VDC for the first two seconds of injection.
Troubleshooting, “Replacing the ECM”. The voltage did not decrease to 5 ± 3 VDC for the
Verify that the problem is resolved. remainder of the injection duration. Proceed to test
step 9.
STOP.
Test Step 9. Check the Battery Voltage
Test Step 8. Check the Voltage at the to the Ether Start Relay and to the Ether
Ether Solenoid(s) Hold Relay
A. Turn the keyswitch to the OFF position. A. Disconnect the connector for the ether start relay
and the connector for the ether hold relay.
B. Disconnect the ether solenoid connector at the
solenoid(s). B. Measure the voltage between terminal 1 of the
connector for the ether start relay and ground.
C. Connect a voltmeter to terminal 1 and terminal 2
of the ether solenoid connector(s). C. Measure the voltage between terminal 4 of the
connector for the ether hold relay and ground.
D. Turn the keyswitch to the ON position.
Expected Result:
NOTICE
Do not allow the ether injection system to be on for The voltage measures 24 ± 3 VDC.
more than two minutes. Damage to the ether solenoid
may occur. Results:
Repair: If ether is not being injected, replace • OK - Ether hold relay – The voltage measures 24
the ether solenoid(s). Verify that the system is ± 3 VDC at the connector for the ether hold relay.
operating correctly. Reconnect the connector for the ether hold relay.
Proceed to Test Step 10.
STOP.
• Not OK – The voltage does not measure 24 ± 3
VDC.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 103/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
104 RENR5622
Troubleshooting Section
Repair: Verify that the breaker for the starting aid C. Connect the positive lead of the multimeter to
is not tripped. Check the wiring between the relay terminal 2 and the negative lead to terminal 1 of
connectors and the battery for an open circuit or the resistor and the diode assembly and observe
for a short circuit. the multimeter.
A. Turn the keyswitch to the OFF position. E. Repeat the measurements for all of the resistor
and the diode assemblies if more than one resistor
B. Disconnect the connector at the resistor and the and diode assembly is present.
diode assembly.
Expected Result:
C. Connect a voltmeter between terminal 1 of the
resistor and the diode assembly and ground. When the positive lead of the multimeter is connected
to terminal 2 and the negative lead to terminal 1, the
D. Turn the keyswitch to the ON position. multimeter displays an overload “(OL)” condition.
E. Activate the ether override and observe the • OK – The resistor and the diode assembly is
voltmeter while ether injection is activated. Disable operating correctly.
the ether override.
Repair: There is a problem in the harness between
Expected Result: the resistor and diode assembly and the ether
solenoid(s). Repair the connectors or wiring and/or
The voltage is 24 ± 3 VDC. replace the connectors or wiring. Verify that the
system is operating correctly. Replace the ether
Results: canister on the ether solenoid.
B. Set the multimeter to the “Check Diode” setting. D. Observe the parameter for the starting aid switch
on Cat ET.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 104/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 105
Troubleshooting Section
E. Obtain a suitable piece of wire. Short the wires c. Observe the parameter for the starting aid
from the starting aid switch together at the starting switch on Cat ET.
aid switch.
H. Check the operation of the ECM by creating a
F. Observe the parameter for the starting aid switch short circuit at the ECM:
on Cat ET.
a. Short the jumper wires for the starting aid
G. Remove the jumper. Leave the wires disconnected switch together.
from the starting aid switch.
b. Observe the parameter for the starting aid
Expected Result: switch on Cat ET.
The parameter for the starting aid switch displays I. Remove the jumper wires. Return all wiring to the
“ON” while the wires from the starting aid switch original configuration.
are shorted together. The parameter for the starting
aid switch displays “OFF” when the wires from the Expected Result:
starting aid switch are not shorted together.
The parameter for the starting aid switch displays
Results: “ON” while the wires from the starting aid switch
are shorted together. The parameter for the starting
• OK – The ECM detects the open and the short aid switch displays “OFF” when the wires from the
from the starting aid switch. starting aid switch are not shorted together.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 105/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
106 RENR5622
Troubleshooting Section
i02410957
Table 34
Event Code
Description Conditions which Generate this Code System Response
E095 Fuel Filter Restriction Warning The fuel filter differential pressure switch
opens. The code is active and the code is
logged.
g01208741
Illustration 41
Left side view
(1) Fuel filter differential pressure switch
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 106/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 107
Troubleshooting Section
g01204990
Illustration 42
Schematic
Results:
A. Replace the fuel filter element. All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are
Expected Result: free of corrosion, of abrasion, and of pinch points.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 107/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
108 RENR5622
Troubleshooting Section
• Not OK – There is a problem in the connectors B. Disconnect the J1/P1 ECM connector.
and/or wiring.
C. Install a jumper wire with Deutsch sockets on each
Repair: Repair the connectors or wiring and/or end into the socket for the signal wire of the fuel
replace the connectors or wiring. Ensure that all of filter differential pressure switch.
the seals are properly in place and ensure that the
connectors are completely coupled. D. Install a wire jumper between the wire jumper
in the socket for the return wire of the fuel filter
Verify that the repair eliminates the problem. differential pressure switch.
STOP. E. Short the jumper wires for the fuel filter differential
pressure switch together.
Test Step 3. Check the Switch Circuit
F. Reconnect the ECM connector.
A. Turn the keyswitch to the OFF position.
G. Start the engine. Increase the engine speed to
B. Disconnect the connector for the fuel filter high idle.
differential pressure switch.
H. Monitor the active diagnostic code screen on Cat
C. Install a wire jumper between the terminals of the ET. Check and record any active diagnostic codes.
connector for the fuel filter differential pressure
switch. Install the wire jumper on the harness side Note: Wait at least 30 seconds in order for the
of the connector. diagnostic codes to become active.
D. Start the engine. Increase the engine speed to I. Remove the short between the jumper wires for
high idle. the fuel filter differential pressure switch.
E. Monitor the active diagnostic code screen on Cat J. Monitor the active diagnostic code screen on Cat
ET. Check and record any active diagnostic codes. ET. Check and record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the Note: Wait at least 30 seconds in order for the
diagnostic codes to become active. diagnostic codes to become active.
F. Check for an event code for the engine fuel filter Expected Result:
restriction.
The event code is not active when the jumper wires
Expected Result: are shorted together. The event code is active when
the jumper wires are not shorted together.
The event code is not active.
Results:
Results:
• OK – The ECM detects the open and the short.
• OK – The event code is not active. The wiring
between the connector and the ECM is OK. Repair: There is an open or a short in the wiring
between the connector for the fuel filter differential
Repair: Check for a plugged fuel filter. If the pressure switch and the ECM. Repair the
fuel filter is OK, temporarily replace the fuel filter connectors or wiring and/or replace the connectors
differential pressure switch. Verify that the problem or wiring. Check the harness connector to the
is resolved before permanently replacing the fuel fuel filter differential pressure switch for a good
filter differential pressure switch. connection.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 108/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 109
Troubleshooting Section
STOP.
i02411006
Ground Level Shutdown
Switch
SMCS Code: 1901-038
Table 35
Diagnostic Code
Description Conditions which Generate this Code System Response
MID 0036 - CID 0267 - FMI 02 Incorrect The two inputs from the ground level The code is active and the code is
Engine Shutdown Switch inputs shutdown switch are in the same state. logged.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 109/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
110 RENR5622
Troubleshooting Section
g01205050
Illustration 44
Schematic
Expected Result:
Results:
Test Step 1. Inspect Electrical Connectors Test Step 2. Check the Status of the
and Wiring Ground Level Shutdown Switch on Cat
ET
A. Turn the keyswitch to the OFF position.
A. Connect Cat ET to the service tool connector.
B. Thoroughly inspect the ECM connector J1/P1. Start Cat ET.
Thoroughly inspect the connectors for the ground
level shutdown switch. Refer to Troubleshooting, B. Turn the keyswitch to the ON position.
“Inspecting Electrical Connectors” for details.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 110/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 111
Troubleshooting Section
C. Operate the ground level shutdown switch. I. Observe the status of the ground level shutdown
Observe the status for the ground level shutdown switch on Cat ET.
switch on Cat ET.
J. Turn the keyswitch to the OFF position.
Expected Result:
K. Remove the wire short.
The status of the ground level shutdown switch reads
“ON” with the ground level shutdown switch in the Expected Result:
SHUTDOWN position. The status of the ground level
shutdown switch reads “OFF” when the ground level The status of the ground level shutdown switch reads
shutdown switch is in the RUN position. “OFF” when the wire F716-WH and the wire 998-BR
are shorted together. The ground level shutdown
Results: switch status reads “ON” when the wire F715-PU and
the wire 998-BR are shorted together.
• OK – The status of the ground level shutdown
switch reads “ON” with the ground level shutdown Results:
switch in the SHUTDOWN position. The status
of the ground level shutdown switch reads “OFF” • OK – The status of the ground level shutdown
when the ground level shutdown switch is in the switch reads “OFF” when the wire F716-WH and
RUN position. The ground level shutdown switch is the wire 998-BR are shorted together. The ground
operating normally. level shutdown switch status reads “ON” when the
wire F715-PU and the wire 998-BR are shorted
Repair: There may be an intermittent problem. If together. The problem is not with the harness or
the problem is intermittent, refer to Troubleshooting, the ECM.
“Inspecting Electrical Connectors”.
Repair: Temporarily connect a new ground level
STOP. shutdown switch. Verify that the new ground level
shutdown switch solves the problem before you
• Not OK – The status of the ground level switch permanently install the new ground level shutdown
does not read “ON” with the ground level shutdown switch.
switch in the SHUTDOWN position. The status of
the ground level shutdown switch does not read STOP.
“OFF” when the ground level shutdown switch is
in the RUN position. The ground level shutdown • Not OK – The status of the ground level shutdown
switch is not operating normally. Proceed to Test switch does not read “OFF” when the wire
Step 3. F716-WH and the wire 998-BR are shorted
together. The ground level shutdown switch status
Test Step 3. Short the Wires together at does not read “ON” when the wire F715-PU and
the Ground Level Shutdown Switch the wire 998-BR are shorted together. There is a
problem in the harness and/or the ECM. Proceed
A. Turn the keyswitch to the OFF position. to Test Step 4.
B. Record the position of the wiring on the ground Test Step 4. Short the Ground Level
level shutdown switch before removing the wires. Shutdown Switch at the ECM
C. Disconnect the wires from the ground level A. Disconnect the ECM connector J1/P1.
shutdown switch.
B. Remove the wire F715-PU at the ECM connector
D. Create a short circuit at the ground level shutdown P1-23. Remove the wire F716-WH at the ECM
switch between the wire F716-WH and the digital connector P1-28 and the digital return wire
return wire 998-BR. Leave the wire F715-PU open. 998-BR from ECM connector P1-5.
E. Turn the keyswitch to the ON position. C. Insert a wire with socket terminals at each end
into the ECM connector P1-28, P1-23 and P1-5.
F. Observe the status of the ground level shutdown Short the wire jumpers in P1-28 and P1-5.
switch on Cat ET.
D. Reconnect all the connectors.
G. Remove the short between the wire F716-WH and
the wire 998-BR. E. Turn the keyswitch to the ON position.
G. Turn the keyswitch to the OFF position. Use this procedure to troubleshoot the electrical
system if a problem is suspected with the injectors
H. Remove the short between P1-28 and P1-5. or if any one of the diagnostic codes in Table 36 is
active or easily repeated.
I. Short the wire jumpers in P1-23 and P1-5.
Expected Result:
Results:
STOP.
STOP.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 112/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 113
Troubleshooting Section
Table 36
solenoid.
MID 0036 - CID 0004 - FMI 06 Cylinder The ECM detects a short circuit. The code is logged.
#4 Injector short The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
MID 0036 - CID 0005 - FMI 05 Cylinder The engine’s ECM detects an open The code is logged.
#5 Injector open circuit circuit. The ECM continues to fire the injector
solenoid.
MID 0036 - CID 0005 - FMI 06 Cylinder The ECM detects a short circuit. The code is logged.
#5 Injector short The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
MID 0036 - CID 0006 - FMI 05 Cylinder The engine’s ECM detects an open The code is logged.
#6 Injector open circuit circuit. The ECM continues to fire the injector
solenoid.
MID 0036 - CID 0006 - FMI 06 Cylinder The ECM detects a short circuit. The code is logged.
#6 Injector short The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
(continued)
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 113/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
114 RENR5622
Troubleshooting Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 114/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 115
Troubleshooting Section
Perform this procedure under conditions that are If an open is detected in the solenoid circuit, a
identical to the conditions that exist when the problem diagnostic code is generated. The ECM continues
occurs. Typically, problems with the injector solenoid to try to fire the injector. If a short is detected in the
occur when the engine is warmed up and/or when solenoid circuit, a diagnostic code is generated. The
the engine is under vibration (heavy loads). ECM will disable the solenoid circuit. The ECM will
periodically try to fire the injector. If the short circuit
These engines have Electronic Unit Injectors (EUI) remains, this sequence of events will be repeated
that are mechanically actuated and electronically until the problem is corrected.
controlled. The ECM sends a 105 volt pulse to each
injector solenoid. The pulse is sent at the proper time
and at the correct duration for a given engine load
and speed. The solenoid is mounted on top of the
fuel injector body.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 115/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
116 RENR5622
Troubleshooting Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 116/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 117
Troubleshooting Section
g01205298
Illustration 46
Typical schematic
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 117/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
118 RENR5622
Troubleshooting Section
Expected Result:
Results:
Test Step 1. Check for Connector Damage • OK – No 1-05 to 16-05 or 1-06 to 16-06 are
logged. Proceed to Test Step 3.
A. Remove power from the ECM.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 118/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 119
Troubleshooting Section
• Not OK – A 1-05 to 16-05 is logged. Proceed to Test Step 4. Check the Harness between
Test Step 4. the ECM and the Injector Connectors for
an Open Circuit
• Not OK – A 1-06 to 16-06 is logged. Proceed to
Test Step 5.
A. Remove power from the ECM. A. Remove power from the ECM.
B. Verify that the ECM connector J2/P2 and the B. Disconnect the connectors for the suspect
injector connectors are properly connected. injector(s).
C. Restore power to the ECM. C. Fabricate a jumper wire 100 mm (4 inch) long with
Deutsch pins on both ends of the wire.
D. Start the engine.
D. Insert one end of the jumper wire into the socket
E. Apply a load to the engine. for the suspect injector’s supply wire. Insert the
other end of the jumper wire into the socket for the
F. Perform the following steps on all suspect suspect injector’s return wire. This will replace the
cylinders (solenoids). injector solenoid with a short circuit.
G. Use the diagnostic tests on Cat ET to initiate the E. Restore power to the ECM.
“Cylinder Cutout Test”.
Note: This test will help the service technician verify
H. Run the “Cylinder Cutout Test”. Run the “Cylinder that the ECM can fire the solenoids. Do not try to
Cutout Test”. Disable the suspect cylinder(s) manually crank the engine during this test. The ECM
during the test. will terminate the “Injector Solenoid Test”.
Expected Result: F. Perform the “Injector Solenoid Test” at least two
times.
The results indicated that the remaining injectors
used more fuel when the “Cylinder Cutout Test” G. Repeat this test for each suspect injector. Stop
disabled the suspect injector(s). the “Injector Solenoid Test” before handling the
jumper wire.
Results:
Expected Result:
• OK – There was a noticeable change in fuel usage.
Cat ET displays “Open” for the cylinder with the
Repair: The injectors are firing in all cylinders. jumper wire.
Reset the system and check for diagnostic codes.
Results:
STOP.
• OK – Cat ET displays “Open” for the cylinder with
• Not OK – There was no noticeable change in fuel the jumper wire. There is a problem in the wiring
usage. between the ECM and the injector connector.
Proceed to Test Step 6.
Repair: Verify that the engine valve lash for that
injector is set correctly. Rerun the “Cylinder Cutout
• Not OK – Cat ET displays “Short” for the cylinder
Test”. If the problem is still present, replace the with the jumper wire. The harness between the
injector. If the new injector has a trim code that is ECM and the injector connector does not have an
different from the old injector, change the trim code open circuit. Proceed to Test Step 7.
in the ECM.
STOP.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 119/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
120 RENR5622
Troubleshooting Section
Test Step 5. Check the Harness between a. Disconnect the appropriate suspect injector
the ECM and the Connectors for the wire from the P2 ECM connector. Remove the
Injector for a Short Circuit signal wire for the suspect injector(s) from the
ECM connector.
B. Disconnect the connectors for the suspect f. Monitor the “Active Diagnostic Code” screen on
injector(s). Cat ET. Wait at least 30 seconds for activation
of the code.
C. Restore power to the ECM.
A 05 diagnostic code should be active for the
Note: This test will help the service technician verify suspect injector(s).
that the ECM can fire the solenoids. Do not try to
manually crank the engine during this test. The ECM g. Remove power from the ECM.
will terminate the “Injector Solenoid Test”.
C. Check the operation of the ECM by creating a
D. Perform the “Injector Solenoid Test” at least two short at the ECM.
times.
a. Create a short between the wire jumper for the
Expected Result: suspect signal wire and engine ground.
All of the suspect cylinders indicate “Open” on Cat ET. b. Restore power to the ECM.
Results: Note: This test will help the service technician verify
that the ECM can fire the solenoids. Do not try to
• OK – All cylinders indicate “Open” on Cat ET. manually crank the engine during this test. The ECM
The harness between the ECM and the injector will terminate the “Injector Solenoid Test”.
connector does not have a short circuit. Proceed
to Test Step 7. c. Perform the “Injector Solenoid Test”.
• Not OK – One or more cylinders indicate “Short” d. Monitor the “Active Diagnostic Code” screen on
on Cat ET. Note the cylinders that indicate “Short”. Cat ET. Wait at least 30 seconds for activation
Proceed to Test Step 6. of the code.
A. Remove power from the ECM. A strong electrical e. Remove power from the ECM.
shock hazard is present if power is not removed
from the ECM. f. Remove the wire jumper. Reconnect all wires
and connectors.
B. Check the operation of the ECM by creating an
open at the ECM.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 120/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 121
Troubleshooting Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 121/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
122 RENR5622
Troubleshooting Section
Illustration 49 g01131276
g01131211
Illustration 48
g01131019
Illustration 50
Seal for a three-pin connector (typical example)
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 122/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 123
Troubleshooting Section
Expected Result:
Results:
If moisture or corrosion is evident in the connector, Test Step 2. Check the Wires for Damage
the source of the moisture entry must be found and
to the Insulation
the source of the moisture entry must be repaired.
If the source of the moisture entry is not repaired, A. Carefully inspect each wire for signs of abrasion,
of nicks, and of cuts.
the problem will recur. Simply drying the connector
will not fix the problem. Check the following items
for the possible moisture entry path: Inspect the wires for the following conditions:
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 123/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
124 RENR5622
Troubleshooting Section
A. Visually inspect each terminal in the connector. Each terminal and each connector easily withstands
Verify that the terminals are not damaged. 45 N (10 lb) of pull and each wire remains in the
Verify that the terminals are properly aligned in connector body.
the connector and verify that the terminals are
properly located in the connector. Results:
Repair: Repair the terminals and/or replace the Test Step 5. Check Individual Pin
terminals, as required. Retention into the Socket
Verify that the repair eliminates the problem.
STOP.
g01131604
Illustr ation 53
Diagram for testing pin retention (typical example)
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 124/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 125
Troubleshooting Section
Expected Result:
Results:
Expected Result:
Results:
• Not OK – The connector’s locking mechanism is b. Torque the allen head screw for the 70
damaged or missing. pin ECM connector to 6.0 + 1.5 - 0.5 N·m
(55 + 13 - 4 lb in).
Repair: Repair the connector or replace the
connector, as required. Verify that the repair
eliminates the problem.
STOP.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 125/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
126 RENR5622
Troubleshooting Section
Expected Result:
Results:
Troubleshooting,
specific trip points“Event
for theCode
eventList”
code.for information on
• Not OK – The allen head screws for the ECM
connector or the customer connector is damaged.
STOP.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 126/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 127
Troubleshooting Section
Table 37
MID 0036 - CID 0338 - FMI 05 Pre-lube The engine’s Electronic Control Module
Relay open circuit (ECM) detects an open circuit at the
prelube relay.
The ECM detects a short to battery
voltage at the prelube relay.
MID 0036 - CID 0338 - FMI 06 Pre-lube The engine’s ECM detects a short
Relay short to ground circuit at the prelube relay.
to record
the event the instances
code of improperwhenever
E098 is generated lubrication,
the
prelubrication system is bypassed.
• “Diagnostics”
• “Diagnostic Tests”
• “Override Parameters”
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 127/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
128 RENR5622
Troubleshooting Section
g01205415
Illustration 58
Schematic
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 128/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 129
Troubleshooting Section
Illustration 61 g01149844
Illustration 59
g01205422 A. Turn the keyswitch to the OFF position.
P1 ECM connector
B. Thoroughly inspect the ECM connectors.
(P1-51) Digital return Inspect all of the other connectors for the circuit.
Refer to Troubleshooting, “Inspecting Electrical
Connectors” for details.
C. Perform a 45
wires in the N (10
ECM lb) pull test
connector thaton
areeach of the
associated
with the circuit.
Expected Result:
Results:
A. Connect Cat ET to the service tool connector. • OK – A 06 diagnostic code was active before
disconnecting the connector. A 05 diagnostic code
B. Turn the keyswitch to the ON position. became active after disconnecting the connector.
The harness and the ECM are OK. The problem
C. Monitor the active diagnostic code screen on Cat may be in the prelube relay.
ET. Check and record any active diagnostic codes.
Repair: Temporarily connect a new prelube relay
Note: Wait at least 30 seconds in order for the to the harness, but do not install the new prelube
diagnostic codes to become active. relay. Verify that there are no active diagnostic
codes for the prelube relay. If there are no active
Expected Result: diagnostic codes for the prelube relay, permanently
install the new prelube relay. Clear any logged
No diagnostic codes are active. diagnostic codes.
Results: STOP.
• OK – No diagnostic codes are active, but a • Not OK – A 06 diagnostic code remains active.
problem is suspected in the prelube system. There is a short between the connector for the
Proceed to Test Step 6. prelube relay and the ECM. Leave the connector
for the prelube relay disconnected. Proceed to Test
• Not OK – A 06 diagnostic code is active at this Step 5.
time. Proceed to Test Step 3.
Test Step 4. Create a Short at the
• Not OK – A 05 diagnostic code is active at this Connector for the Prelube Relay
time. Proceed to Test Step 4.
A. Turn the keyswitch to the OFF position.
Test Step 3. Create an Open at the
Connector for the Prelube Relay B. Install a jumper wire between terminal 85 and
terminal 86 of the connector for the prelube relay.
A. Turn the keyswitch to the OFF position.
C. Turn the keyswitch to the ON position.
B. Disconnect the connector for the prelube relay.
Note: Monitor the “Active Diagnostic Codes” screen
C. Turn the keyswitch to the ON position. on Cat ET after installing the jumper wire.
D. Proceed to the “Diagnostic Overrides” screen on D. Proceed to the “Diagnostic Overrides” screen on
Cat ET. Cat ET.
Note: Monitor the “Active Diagnostic Codes” screen Note: Monitor the “Active Diagnostic Codes” screen
on Cat ET. on Cat ET.
F. Check for a 05 diagnostic code for the prelube F. Wait at least 30 seconds for activation of the 06
relay. diagnostic code.
Note: Wait at least 30 seconds in order for the G. Turn the keyswitch to the OFF position. Remove
diagnostic codes to become active. the wire jumper.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 130/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 131
Troubleshooting Section
B. Fabricate jumper wires that can be used to replace I. Turn the keyswitch to the OFF position. Reconnect
the wire(s) in the ECM connector for the prelube all wires to the original configuration.
relay. Crimp a connector socket to one end of the
jumper wires. Expected Result:
C. Disconnect the appropriate ECM connector(s) for A 05 diagnostic code is active when the wires from
the prelube relay. the prelube relay are open at the ECM connector.
A 06 diagnostic code is active if the wires from the
D. Remove the wire(s) for the prelube relay from the prelube relay are shorted at the ECM connector.
ECM connector.
Results:
E. Install the jumper wire(s) into the terminal
location(s) for the prelube relay at the ECM • OK – The ECM is operating properly. The problem
connector. is in the wiring between the ECM and the connector
for the prelube relay.
F. Connect the ECM connectors.
Repair: Repair the connectors or wiring and/or
G. Check the operation of the ECM by creating replace the connectors or wiring.
an open at the ECM:
STOP.
a. Hold the loose end of the jumper wire away
from any components in order to create an • Not OK – One of the following conditions exists:
open circuit condition. The 05 diagnostic code is not active when the
wire for the prelube relay is disconnected. The 06
b. Turn the keyswitch to the ON position. diagnostic code is not active when the wire jumper
is installed.
c. Proceed to the “Diagnostic Overrides” screen
on Cat ET. Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”.
d. Activate the prelube system. Verify that the problem is resolved.
Test Step 6. Check the Voltage to the Coil Test Step 7. Check the Voltage at the
of the Prelube Switch Prelube Motor
A. Disconnect wire 337-WH from the coil of the A. Disconnect the wire to the prelube motor from the
prelube switch. prelube switch at the prelube motor.
B. Connect a voltmeter between wire 337-WH and B. Connect a voltmeter between the wire and engine
engine ground. ground.
C. Turn the keyswitch to the ON position. C. Turn the keyswitch to the ON position.
D. Proceed to the “Diagnostic Overrides” screen on D. Proceed to the “Diagnostic Overrides” screen on
Cat ET. Cat ET.
F. Measure the voltage between wire 337-WH and F. Measure the voltage between the wire and engine
engine ground. ground.
G. Turn the keyswitch to the OFF position. G. Turn the keyswitch to the OFF position.
H. Replace all wires to the original configuration. H. Replace all wires to the original configuration.
Results: Results:
• OK – The voltage is 24 ± 3 VDC. Proceed to Test • OK – The voltage is 24 ± 3 VDC. Proceed to Test
Step 7. Step 8.
• Not OK – The voltage is not 24 ± 3 VDC. • Not OK – The voltage is not 24 ± 3 VDC.
Repair: Perform the following steps. Repair: Perform the following steps.
1. Remove wire 337-WH from terminal 85 on the 1. Remove the wire to the prelube motor from the
prelube relay. Activate the prelube override and prelube switch at the prelube switch. Activate
measure the voltage between terminal 85 on the prelube override and measure the voltage
the prelube relay and engine ground. If voltage between the terminal on the prelube switch
is present on terminal 85 on the prelube relay, and engine ground. If voltage is present on the
repair the wire 337-WH. terminal, repair the wire to the prelube motor.
If 24 ± 3 VDC is not present on terminal 85 2. If voltage is not present on the terminal, verify
on the prelube relay, measure the voltage to that the wire 200-BK has continuity to engine
terminal 30 on the prelube relay. If 24 ± 3 VDC ground. If wire 200-BK has continuity to engine
is not present on terminal 30 of the prelube ground, measure the voltage to the other side of
relay, verify that the 20A start aid breaker is the contacts of the prelube switch. If 24 ± 3 VDC
not tripped. Verify that the wiring between the is present on the contacts of the prelube switch
battery and the prelube relay is OK. and the wire 200-BK is not open, replace the
prelube switch and retest the prelube system.
2. If 24 ± 3 VDC is present on terminal 30 on the
prelube relay, replace the prelube relay and 3. If 24 ± 3 VDC is not present on the other side
retest the prelube system. of the contacts of the prelube switch, repair
the wiring between the battery and the prelube
STOP. switch.
STOP.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 132/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 133
Troubleshooting Section
Expected Result:
Results:
STOP.
STOP.
i02412085
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 133/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
134 RENR5622
Troubleshooting Section
Table 38
System Operation
• Terminal A 8 V supply
• Terminal B sensor return
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 134/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 135
Troubleshooting Section
Illustration 62 g01208743
Sensor locations
(1) Left exhaust temperature sensor (2) Right exhaust temperature sensor
g01205563
Illustration 63
Typical schematic
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 135/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
136 RENR5622
Troubleshooting Section
g01205567 g01205569
Illustration 64 Illustration 65
P1 ECM connector P2 ECM connector
(P1-4) 8 V supply (P2-55) Digital return
(P1-11) Left exhaust temperature
(P1-12) Right exhaust temperature
(P1-60) Digital return
g01094844
Illustration 66
Sensor connector
(Pin
(Pin A)
B) Sensor
Sensor supply
return
(Pin C) Signal
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 136/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 137
Troubleshooting Section
Note: Wait at least 30 seconds in order for the • Not OK – At least one intermittent problem was
diagnostic codes to become active. indicated.
C. Determine if a diagnostic code has occurred Repair: Repair the harness or the connector. Refer
several times. to the diagnostic functional test Troubleshooting,
“Inspecting Electrical Connectors”. Verify that the
Note: A diagnostic code that is logged several repair eliminates the problem.
times is an indication of an intermittent problem.
Most intermittent problems are the result of a bad STOP.
connection between a socket and a pin in a connector
or a bad connection between a wire and a terminal. Test Step 3. Check the Digital Supply
Voltage at the Sensor Connector
D. Determine if a 08 diagnostic code is active or if a
08 diagnostic code has been logged. A. Disconnect the suspect sensor(s) at the sensor
connector:
Expected Result:
B. Measure the voltage on the ECM side of the
No diagnostic code is active for the exhaust sensor connector between pin A and pin B for the
temperature sensors. suspect sensor(s).
• OK – No diagnostic codes are active. The supply voltage is 8.0 ± 0.4 VDC.
Test Step 2. Perform the “Wiggle Test” A. Remove power from the ECM.
on Cat ET
B. Remove the supply wire from P1-4. Install a wire
A. Select the “Wiggle Test” from the diagnostic tests jumper into the socket for P1-4.
on Cat ET.
C. Restore power to the ECM.
B. Choose the appropriate group of parameters to
monitor. D. Measure the voltage between the wire jumper in
terminal P1-4 and engine ground.
C. Press the “Start” button. Wiggle the wiring harness
for the suspect sensor in order to reproduce an E. Remove power from the ECM.
intermittent problem.
F. Remove the wire jumper and reconnect all wires.
If an intermittent problem is detected, the status will Reconnect ECM connector J1/P1.
be highlighted and an audible beep will be heard.
Expected Result:
Expected Result:
The supply voltage is 8.0 ± 0.4 VDC.
No intermittent problems were detected during the
“Wiggle Test”. Results:
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 137/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
138 RENR5622
Troubleshooting Section
Repair: Repair the connectors or wiring and/or B. Remove the suspect signal wire for the sensor
replace the connectors or wiring. from ECM connector P1. Refer to Illustration 63
for the terminal locations for the ECM connector.
STOP.
C. Restore power to the ECM.
• Not OK – The supply voltage is not 8.0 ± 0.4 VDC.
The voltage at the ECM is not correct. D. Measure the duty cycle between the sensor’s
signal wire and the sensor’s return wire.
Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”. Note: Set the multimeter to “VDC”. Press the “Hz”
Verify that the problem is resolved. button twice so that the % symbol is displayed.
A. Remove power from the ECM. The duty cycle is between 10 to 90 percent.
Results:
Sensor Supply
SMCS Code: 5574-038
• OK – The duty cycle is correct. Proceed to Test
Step 6. System Operation Description:
• Not OK – The duty cycle is incorrect. Use this procedure to troubleshoot the electrical
system if a problem is suspected with a sensor
Repair: Replace the sensor. Verify that no
diagnostic codes are active for the suspect sensor supply or if any
39 is active one ofrepeated.
or easily the diagnostic codes in Table
before permanently installing the sensor.
STOP.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 138/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 139
Troubleshooting Section
Table 39
MID 0036 - CID 0262 - FMI 04 5 Volt The analog sensor supply voltage is
Sensor DC Power Supply short to below normal for two seconds.
ground
MID 0036 - CID 0263 - FMI 03 Digital The digital sensor supply voltage is
Sensor Supply short to +batt above normal for two seconds.
MID 0036 - CID 0263 - FMI 04 Digital The digital sensor supply voltage is
Sensor Supply short to ground below normal for two seconds.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 139/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
140 RENR5622
Troubleshooting Section
g01203777
Illustration 67
Typical 5 V supply
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 140/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 141
Troubleshooting Section
g01205563
Illustration 68
Typical 8 V supply
g01206359 g01206347
Illustration 69 Illustration 70
P1 ECM connector P2 ECM connector
(P1-1) Aftercooler temperature sensor (front) (P2-36) Turbocharger outlet pressure sensor
(P1-2) 5 V sensor supply (P2-37) Atmospheric sensor
(P1-3) Sensor return (P2-38) Left turbocharger inlet pressure sensor
(P1-4) 8 V supply (P2-39) Right turbocharger inlet pressure sensor
(P1-6) Aftercooler temperature sensor (rear) (P2-46) Crankcase pressure sensor
(P1-7) Coolant temperature sensor (P2-55) Digital return
(P1-11) Left exhaust temperature
(P1-12) Right exhaust temperature
(P1-16) Filtered engine oil pressure sensor
(P1-17) Unfiltered engine oil pressure sensor
(P1-18) 5 V sensor supply
(P1-35) Sensor return
(P1-60) Digital return
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 141/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
142 RENR5622
Troubleshooting Section
STOP.
Test Step 2. Check for Active Diagnostic
Codes
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.
g01094844
Illustration 71
B. Restore power to the ECM.
Sensor connector
(Pin A) Sensor supply C. Monitor the active diagnostic code screen on
(Pin B) Sensor return Cat ET. Check and record any active diagnostic
(Pin C) Signal codes. Look for the following diagnostic codes:
Results:
• Not OK – Either the 263-03 or 263-04 diagnostic
code is active at this time. Proceed to Test Step 5.
• OK – The harness and connectors appear to be Test Step 3. Disconnect the 5 Volt
OK. Proceed to Test Step 2. Sensors while you Monitor the Active
Diagnostic Codes
• Not OK – There is a problem with the connectors
and/or wiring. A. Monitor the active diagnostic code screen on Cat
ET while you disconnect each 5 Volt sensor at
the sensor connector. Check for an active 262-03
code or an active 262-04 code.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 142/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 143
Troubleshooting Section
Note: Wait at least 30 seconds in order for the D. Remove the wires from terminal locations P2-18
diagnostic codes to become active. (5 V sensor supply) and P2-35 (sensor return).
Install a jumper wire into each of these terminal
a. Disconnect the following sensors one at a time: locations.
• Aftercooler temperature sensor (front) F. Restore electrical power to the engine ECM.
• Atmospheric pressure sensor G. Measure the voltage between the jumper wire in
P1-2 (5 V sensor supply) and the jumper wire in
• Coolant temperature sensor P1-3 (sensor return).
• Crankcase pressure sensor H. Measure the voltage between the jumper wire in
P2-18 (5 V sensor supply) and the jumper wire in
• Filtered engine oil pressure sensor P2-35 (sensor return).
• Turbocharger outlet pressure sensor I. Remove electrical power from the ECM.
• Right turbocharger inlet pressure sensor Each voltage measurement is 5.0 ± 0.2 VDC.
B. Remove electrical power from the ECM. • OK – The voltage measurement is 5.0 ± 0.2 VDC.
The ECM is operating correctly.
Expected Result:
Repair: One of the supply wires is shorted to
The diagnostic code deactivates when a particular another wire in the harness or one of the supply
sensor is disconnected. wires is shorted to engine ground. To isolate
the problem to a specific harness, perform the
Results: following test steps:
• OK – The 262-03 or 262-04 diagnostic 1. One at a time, reinstall the wiring for each 5 V
code deactivates when a particular sensor is supply while you check Cat ET for an active
disconnected. 262-03 or 262-04 diagnostic code.
Repair: Connect the suspect sensor. If the code a. Disconnect the ECM connector.
returns, replace the sensor. Connect all of the
connectors. Verify that the problem is resolved. b. Install the wires that were removed for the
5 V supply at the ECM connector. Refer to
STOP. Illustration 67 for wiring information.
B. Fabricate four jumper wires that are long enough f. If a diagnostic code becomes active for
to be used to measure the supply voltage at the this 5 V supply, there is a problem in this
ECM connectors. Crimp connector sockets to one harness between the ECM and the sensor
end of each jumper wire. connector.
2. Repair the wiring and/or the connector. Replace B. Fabricate two jumper wires that are long enough
parts, if necessary. Verify that the problem is to be used to measure the supply voltage at the
resolved. ECM connectors. Crimp connector sockets to one
end of each jumper wire.
STOP.
C. Remove the wires from terminal locations P1-4 (8
• Not OK – The voltage measurement is not 5.0 ± V sensor supply) and P1-60 (sensor return). Install
0.2 VDC. a jumper wire into each of these terminal locations.
Repair: Replace the ECM. Refer to D. Connect the J1/P1 ECM connector.
Troubleshooting, “Replacing the ECM”.
E. Restore electrical power to the engine ECM.
STOP.
F. Measure the voltage between the jumper wire
Test Step 5. Disconnect the 8 Volt in P1-4 (8 V sensor supply) and P1-60 (sensor
Sensors while you Monitor the Active return).
Diagnostic Codes
G. Remove electrical power from the ECM.
A. Monitor the active diagnostic code screen on Cat
ET while you disconnect each 8 Volt sensor at Expected Result:
the sensor connector. Check for an active 263-03
code or an active 263-04 code. The voltage measurement is 8.0 ± 0.4 VDC.
• Exhaust temperature sensor (LH) Repair: One of the supply wires is shorted to
another wire in the harness or one of the supply
• Exhaust temperature sensor (RH) wires is shorted to engine ground. To isolate
the problem to a specific harness, perform the
B. Remove electrical power from the ECM. following test steps:
Expected Result: 1. Reinstall the wiring for the 8 V supply while you
check Cat ET for an active 263-03 or 263-04
The diagnostic code deactivates when a particular diagnostic code.
sensor is disconnected.
a. Disconnect the ECM connector.
Results:
b. Install the wires that were removed for the
• OK – The 263-03 or 263-04 diagnostic 8 V supply at the ECM connector. Refer to
code deactivates when a particular sensor is Illustration 67 for wiring information.
disconnected.
c. Connect the ECM connector.
Repair: Connect the suspect sensor. If the code
returns, replace the sensor. Connect all of the d. Restore electrical power to the engine ECM.
connectors. Verify that the problem is resolved.
e. Monitor the active diagnostic code screen on
STOP. Cat ET. Check for an active 263-03 code or
an active 263-04 code.
• Not OK – The 263-03 or 263-04 diagnostic code
remains active after the sensors are disconnected. Note: Wait at least 30 seconds in order for the
Leave the sensors disconnected. The sensors are diagnostic codes to become active.
not the cause of the diagnostic code. Proceed to
Test Step 6. f. If a diagnostic code becomes active for
this 8 V supply, there is a problem in this
Test Step 6. Check the 8 Volt Supply harness between the ECM and the sensor
Voltage at the ECM connector.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 144/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 145
Troubleshooting Section
STOP.
STOP.
i02413879
Table 40
frequency
for that is greater than 1000 Hz
two seconds.
or
The engine’s ECM detects a duty cycle
that is less than 5 percent or a duty
cycle that is greater than 95 percent for
one second.
throttle
cycle ofposition sensor.
the signal into a The ECM
usable converts
throttle the duty
position. The
duty cycle must be between 5 percent and 95 percent
for a valid signal. The frequency of the signal must be
a fixed frequency between 150 Hz and 1000 Hz. The
ECM displays the throttle position as a percentage
between 0 and 100 percent.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 145/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
146 RENR5622
Troubleshooting Section
g01206563
Illustration 72
Typical schematic
g01151263 g01206568
Illustration 73 Illustration 74
P1 ECM connector Machine connector
(P1-4) +8 V digital supply (Terminal 8) +8 V digital supply
(P1-5) Digital return (Terminal 9) Digital return
(P1-10) Throttle signal (Terminal 10) Throttle signal
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 146/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 147
Troubleshooting Section
• Not OK – The throttle assembly is not operating A. Turn the keyswitch to the OFF position.
correctly.
B. Disconnect the connector for the throttle position
Repair: Repair the throttle assembly or replace sensor.
the throttle assembly. The throttle assembly
should operate smoothly without excessive drag. C. Turn the keyswitch to the ON position.
The throttle assembly should return to the low
idle position without assistance in less than one D. Measure the sensor supply voltage at the
second. connector between Terminal A and Terminal B.
Test Step 2. Check the Throttle Position The voltage is 8.0 ± 0.4 VDC.
with Caterpillar Electronic Technician
(ET) Results:
A. Connect Cat ET to the service tool connector. • OK – The voltage is 8.0 ± 0.4 VDC. The supply
Start Cat ET. voltage is reaching the sensor. Proceed to Test
Step 4.
B. Turn the keyswitch to the ON position.
• Not OK – The voltage is not 8.0 ± 0.4 VDC. The
C. Observe the throttle position reading on Cat ET. supply voltage is not reaching the sensor. Proceed
to Test Step 7.
D. Depress the throttle and release the throttle.
Test Step 4. Check the Duty Cycle at the
Expected Result: Throttle Position Sensor Connector
The throttle position reads 0 percent when the throttle A. Turn the keyswitch to the OFF position.
pedal is released. The throttle position increases
to 100 percent when the throttle pedal is fully B. Remove wire F702-GN from Terminal C at the
depressed. sensor connector.
• OK – The throttle position reads 0 percent when D. Measure the duty cycle between wire F702-GN
the throttle pedal is released. The throttle position and Terminal B at the sensor connector.
increases to 100 percent when the throttle pedal is
fully depressed. The throttle position sensor is OK. Note: Set the multimeter to “VDC”. Press the “Hz”
button twice so that the % symbol is displayed.
Repair: There may be an intermittent problem. If
the problem is intermittent, perform the diagnostic E. Depress the throttle and release the throttle.
functional test Troubleshooting, “Inspecting
Electrical Connectors”. F. Turn the keyswitch to the OFF position.
Expected Result:
• OK – A valid duty cycle is present at the sensor D. Turn the keyswitch to the OFF position.
connector. Proceed to Test Step 5.
Expected Result:
• Not OK – A valid duty cycle is not present at the
sensor connector. The throttle position reads 0 percent when the throttle
pedal is released. The throttle position increases
Repair: Replace the throttle position sensor. Verify to 100 percent when the throttle pedal is fully
that the new sensor is operating correctly. depressed.
A. Remove wire F702-GN from P1-10 at the ECM • OK – The throttle position reads 0 percent when
connector P1. the throttle pedal is released. The throttle position
increases to 100 percent when the throttle pedal
B. Turn the keyswitch to the ON position. is fully depressed. The throttle position sensor is
OK. There is an intermittent problem in the wiring
C. Measure the duty cycle between wire F702-GN and/or connectors between the ECM and the
and P1-5 of ECM connector J1/P1. throttle position sensor.
Note: Set the multimeter to “VDC”. Press the “Hz” Repair: If the problem is intermittent, perform
button twice so that the % symbol is displayed. the diagnostic functional test Troubleshooting,
“Inspecting Electrical Connectors”.
D. Depress the throttle and release the throttle.
STOP.
E. Turn the keyswitch to the OFF position.
• Not OK – The throttle position does not read 0
F. Reconnect all connectors and wires. percent when the throttle pedal is released. The
throttle position does not increase to 100 percent
Expected Result: when the throttle pedal is fully depressed.
The duty cycle is between 6 and 10 percent when the Repair: The ECM is not reading the throttle
throttle is released. The duty cycle is between 85 and position sensor signal correctly. Replace the ECM.
94 percent when the throttle is fully depressed. Refer to the diagnostic procedure Troubleshooting,
“Replacing the ECM.”.
Results:
STOP.
• OK – A valid duty cycle is present at the ECM
connector. Proceed to Test Step 6. Test Step 7. Check the 8 Volt Supply
Voltage at the ECM
• Not OK – A valid duty cycle is not present at the
ECM connector. A. Disconnect the J1/P1 ECM connector.
Repair: There is a problem in the wiring and/or B. Fabricate two jumper wires that are long enough
connectors between the ECM and the throttle to be used to measure the supply voltage at the
position sensor. Repair the connectors or wiring ECM connectors. Crimp connector sockets to one
and/or replace the connectors or wiring. end of each jumper wire.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 148/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 149
Troubleshooting Section
Expected Result:
Results:
STOP.
STOP.
i02414014
Table 41
E265 User Defined Shutdown The engine’s Electronic Control Module The code is logged.
(ECM) detects ground on the input for
the user defined shutdown.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 149/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
150 RENR5622
Troubleshooting Section
g01206647
Illustration 75
Typical schematic
g01206650 g01206655
Illustration 76 Illustration 77
P1 ECM Connector Machine Connector
(P1-21) User defined shutdown (Terminal 13) User defined shutdown
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 150/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 151
Troubleshooting Section
C. Perform a 45 N (10 lb) pull test on each of the Test Step 3. Create a Short at the
wires in the ECM connector that are associated Connector for the User Defined
with the circuit. Shutdown
D. Check the allen head screw on each ECM A. Use a jumper wire with a socket terminal at one
connector for the proper torque. Refer end to short wire F721-GY to the chassis ground.
to Troubleshooting, “Inspecting Electrical Create the short at the connector for the user
Connectors” for the correct torque values. defined shutdown.
E. Check the harness and the wiring for abrasion Expected Result:
and for pinch points.
Cat ET indicates “User Shutdown ON” when the wire
Expected Result: F721-GY is shorted to chassis ground.
A. Ensure that the user defined shutdown switch is in A. Turn the keyswitch to the OFF position.
the OFF position.
B. Disconnect ECM connector J1/P1.
B. Connect Cat ET to the service tool connector.
Start Cat ET. C. Measure the resistance at the ECM connector
between P1-21 and every pin in ECM connector
C. Engage the parking brake. P1.
D. Turn the keyswitch to the ON position. D. Measure the resistance at the ECM connector
between P1-21 and the engine ground.
E. Observe the status for the user defined shutdown
on Cat ET. Expected Result:
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 151/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
152 RENR5622
Troubleshooting Section
A. Measure the resistance at the ECM connector Repair: Repair the connectors and/or wiring or
between P1-21 and engine ground. replace the connectors or wiring. There may be an
intermittent problem. If the problem is intermittent,
B. Remove the wire short. refer to Troubleshooting, “Inspecting Electrical
Connectors”.
Expected Result:
STOP.
The resistance measurement indicates a short circuit.
• Not OK – Cat ET does not indicate “User
Results: Shutdown ON” with the wire short in place. Cat ET
does not indicate “User Shutdown OFF” when the
• OK – The resistance measurement indicates a wire short is removed. Cat ET does not indicate
short circuit. The resistance is within acceptable the correct status.
limits. Proceed to Test Step 6.
Repair: Replace the ECM. Refer to
• Not OK – The resistance measurement does not Troubleshooting, “Replacing the ECM”.
indicate a short circuit. There is an open circuit or
excessive resistance in the harness. STOP.
STOP.
Wastegate Solenoid
SMCS Code: 1057-038
Test Step 6. Short the Wire at the ECM
System Operation Description:
A. Remove the wire from the ECM connector at
P1-21. Use this procedure to troubleshoot any suspect
problems with the wastegate solenoid.
B. Insert a wire with a socket terminal at one end into
the ECM connector at P1-21. Use this procedure if a problem is suspected with the
wastegate solenoid or if any one of the diagnostic
C. Reconnect ECM connector J1/P1. codes in Table 42 is active or easily repeated.
D. Turn the keyswitch to the ON position.
Expected Result:
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 152/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 153
Troubleshooting Section
Table 42
g01206721
Illustration 78
Typical schematic
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 153/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
154 RENR5622
Troubleshooting Section
Results:
STOP.
All connectors, pins, and sockets are completely • Not OK – A 05 diagnostic code is active at this
coupled and/or inserted. The harness and wiring are time. Proceed to Test Step 4.
free of corrosion, of abrasion, and of pinch points.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 154/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 155
Troubleshooting Section
Test Step 3. Create an Open at the B. Install a jumper wire between terminal 1 and
Connector for the Wastegate Solenoid terminal 2 of the connector for the wastegate
solenoid.
A. Turn the keyswitch to the OFF position.
C. Turn the keyswitch to the ON position.
B. Disconnect the connector for the wastegate
solenoid. D. Proceed to the “Diagnostic Overrides” screen on
Cat ET.
C. Turn the keyswitch to the ON position.
E. Select the override for the wastegate on Cat ET.
D. Proceed to the “Diagnostic Overrides” screen on
Cat ET. F. Set the override for the wastegate to 100 percent.
E. Select the override for the wastegate solenoid on G. Wait at least 30 seconds for activation of the 06
Cat ET. diagnostic code.
F. Set the override for the wastegate solenoid to 100 H. Turn the keyswitch to the OFF position. Remove
percent. the wire jumper.
E. Install the jumper wire(s) into the terminal I. Turn the keyswitch to the OFF position. Reconnect
location(s) for the wastegate solenoid at the ECM all wires to the original configuration.
connector.
Expected Result:
F. Connect the ECM connectors.
A 05 diagnostic code is active when the wires
G. Check the operation of the ECM by creating from the wastegate solenoid are open at the ECM
an open at the ECM: connector. A 06 diagnostic code is active if the wires
from the wastegate solenoid are shorted at the ECM
a. Hold the loose end of the jumper wires away connector.
from any components in order to create an
open circuit condition. Results:
b. Turn the keyswitch to the ON position. • OK – The ECM is operating properly. The problem
is in the wiring between the ECM and the connector
c. Proceed to the “Diagnostic Overrides” screen for the wastegate solenoid.
on Cat ET.
Repair: Repair the connectors or wiring and/or
d. Select the override for the wastegate solenoid replace the connectors or wiring.
on Cat ET.
STOP.
e. Set the override for the wastegate to 100
percent. • Not OK – One of the following conditions exists:
The 05 diagnostic code is not active when the wire
f. Monitor the “Active Diagnostic Code” screen for the wastegate solenoid is disconnected. The 06
on Cat ET. diagnostic code is not active when the wire jumper
is installed.
Check the wastegate solenoid for an active 05
diagnostic code. Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”.
Note: Wait at least 30 seconds so that any codes Verify that the problem is resolved.
may become active.
STOP.
g. Turn the keyswitch to the OFF position.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 156/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 157
Troubleshooting Section
Calibration Procedures
i02415146
Table 43
The engine speed/timing sensor is calibrated B. Connect Caterpillar Electronic Technician (ET) to
through a two-step process. A new timing reference the service tool connector.
is calculated first. The reference is based on
the signals from the transducer and the engine C. Remove the timing calibration plug from the
speed/timing sensor. Next, the new timing reference flywheel housing.
is programmed into the permanent memory of the
engine’s Electronic Control Module (ECM). D. Examine the flywheel through the timing
calibration hole. Ensure that the probe is not
The engine speed/timing sensor provides engine inserted into the timing pin hole. If necessary,
information to the ECM. The ECM powers the engine rotate the engine.
speed/timing sensor with 12.5 ± 1.0 VDC. The sensor
senses the tooth pattern on the timing reference gear E. Install the 6V-3093 Transducer Adapter into the
that is attached to the left camshaft. As the timing hole for the timing calibration at the flywheel.
gear rotates past the engine speed/timing sensor, a
signal is generated in the sensor. This signal is sent F. Insert the 6V-2197 Transducer through the
to the ECM. The ECM uses this signal in order to 6V-3093 Transducer Adapter. Insert the
calculate the engine position and the engine speed. transducer until contact is made with the surface
of the flywheel. Move the transducer 0.9 mm
A loss of the engine speed/timing signal causes the (0.04 inch) away from the flywheel.
ECM to stop sending power to the fuel injectors.
NOTICE
Calibration of the timing is required only after the Do not install the timing calibration probe over the tim-
following circumstances: ing pin hole in the flywheel or damage will result.
• The ECM has been replaced.
G. Tighten the nut on the 6V-3093 Transducer
• The speed/timing sensor has been replaced. Adapter.
• The timing gear and/or the rear gear train have H. Connect the 7X-1695 Cable As between the
been adjusted. transducer and the timing calibration connector
P26.
• The timing gear and/or the rear gear train have
been replaced. I. Turn the keyswitch to the START position.
Test Step 1. Check for an “ACTIVE” J. Start the engine. Allow the engine to exit cold
Diagnostic Code. mode operation.
A. Turn the keyswitch to the OFF position. K. Monitor the diagnostic codes on Cat ET. Check
and record any diagnostic codes.
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 157/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
158 RENR5622
Troubleshooting Section
Note: Wait at least 15 seconds in order for the Repair: Disconnect the timing calibration probe
diagnostic codes to become active. before you exit the “Timing Calibration” screen
on Cat ET. Reset the system and check for any
Expected Result: diagnostic codes.
STOP.
Expected Result:
Results:
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 158/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 159
Index Section
Index
A Electrical Connectors and Functions..................... 12
Engine Electronic Control Module (ECM) .......... 12
Alternator (Noisy Operation) .................................. 36 Machine Connector............................................ 13
Probable Causes ............................................... 36 Sensor Connectors ............................................ 14
Recommended Actions...................................... 36 Service Tool Connector for Cat ET .................... 13
Analog Sensor (Active).......................................... 65 Electrical Power Supply......................................... 80
Electronic Service Tool Will Not Communicate with
ECM..................................................................... 44
B Probable Causes ............................................... 44
Recommended Actions...................................... 44
Boost Pressure Above Normal .............................. 37 Electronic Service Tools ........................................ 14
Probable Causes ............................................... 37 Caterpillar Electronic Technician (ET)................ 15
Recommended Actions...................................... 37 Optional Service Tools ....................................... 15
Boost Pressure Below Normal............................... 37 Required Service Tools ...................................... 14
Probable Causes ............................................... 38 Electronic Troubleshooting ...................................... 4
Engine Cranks but Will Not Start........................... 45
Probable Causes ............................................... 45
C Recommended Actions...................................... 45
Engine Has Early Wear ......................................... 46
Calibration Procedures........................................ 157 Probable Causes ............................................... 46
Can Not Reach Top Engine RPM .......................... 39 Recommended Actions...................................... 46
Probable Causes ............................................... 39 Engine Misfires, Runs Rough or Is Unstable......... 47
Recommended Actions...................................... 39 Probable Causes ............................................... 47
Cat Data Link ......................................................... 73 Recommended Actions...................................... 47
Coolant Flow Switch.............................................. 76 Engine Oil in Cooling System................................ 48
Coolant in Engine Oil............................................. 40 Probable Causes ............................................... 48
Probable Causes ............................................... 40 Recommended Actions...................................... 48
Recommended Actions...................................... 40 Engine Oil Level Switch......................................... 85
Coolant Temperature Is Too High .......................... 41 Engine Oil Renewal Solenoid................................ 89
Probable Causes ............................................... 41 Engine Overspeed................................................. 48
Recommended Actions...................................... 42 Probable Causes ............................................... 49
Coolant Temperature Is Too Low........................... 40 Recommended Actions...................................... 49
Probable Causes ............................................... 41 Engine Speed/Timing Sensor ................................ 92
Recommended Actions...................................... 41 Engine Speed/Timing Sensor - Calibrate ............ 157
Crankcase Pressure (High) ................................... 42 Engine Stalls at Low RPM..................................... 49
Probable Causes ............................................... 43 Probable Causes ............................................... 49
Recommended Actions...................................... 43 Recommended Actions...................................... 49
Customer Parameters Worksheet ......................... 33 Engine Will Not Crank ........................................... 50
Probable Causes ............................................... 50
Recommended Actions...................................... 50
D Ether Injection System........................................... 96
Event Code List ..................................................... 21
Diagnostic Code List.............................................. 16 Active Event Codes............................................ 22
Active Diagnostic Codes .................................... 21 Clearing Event Codes........................................ 23
Cross-Reference Information for Diagnostic Cross-Reference Information for Event Codes.. 21
Codes...............................................................
Diagnostic Codes............................................... 16
20 Default
LoggedConditions
Event Codes for.........................................
the Monitoring System.... 26 23
Logged Diagnostic Codes.................................. 21 Trip Points for the Monitoring System................ 24
Diagnostic Functional Tests................................... 65 Troubleshooting ................................................. 24
Excessive Black Smoke ........................................ 51
Probable Causes ............................................... 51
E Recommended Actions...................................... 52
Excessive Engine Oil Consumption....................... 51
ECM Will Not Accept Factory Passwords.............. 43 Probable Causes ............................................... 51
Probable Causes ............................................... 43 Recommended Actions...................................... 51
Recommended Actions...................................... 43 Excessive White Smoke........................................ 53
ECM Will Not Communicate with Other Systems or Probable Causes ............................................... 53
Display Modules .................................................. 43 Recommended Actions...................................... 53
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 159/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
160 RENR5622
Index Section
S
G
Self-Diagnostics...................................................... 11
Ground Level Shutdown Switch .......................... 109 Diagnostic Codes................................................ 11
Sensor Supply ..................................................... 138
Symptoms.............................................................. 36
I System Configuration Parameters......................... 30
Injector Trim Code ............................................. 32
Important Safety Information ................................... 2 Parameter Table................................................. 32
Injector Solenoids ................................................. 112 System Overview..................................................... 4
Inlet Air Restriction ................................................ 55 Electronic Controls............................................... 4
Probable Causes ............................................... 56
Recommended Actions...................................... 56
Inspecting Electrical Connectors ......................... 121 T
Intermittent Engine Shutdown ............................... 56
Probable Causes ............................................... 56 Table of Contents..................................................... 3
Recommended Actions...................................... 56 Throttle Position Sensor ...................................... 145
Intermittent Low Power or Power Cutout............... 57 Too Much Valve Lash ............................................ 63
Probable Causes ............................................... 57 Probable Causes ............................................... 63
Recommended Actions...................................... 57 Recommended Actions...................................... 63
Too Much Vibration................................................ 64
Probable Causes ............................................... 64
L Recommended Actions...................................... 64
Troubleshooting Section.......................................... 4
Low Engine Oil Pressure....................................... 58 Troubleshooting without a Diagnostic Code .......... 36
Probable Causes ............................................... 59
Recommended Actions...................................... 59
Low Power/Poor or No Response to Throttle........ 59 U
Probable Causes ............................................... 59
Recommended Actions...................................... 60 User Defined Shutdown Input.............................. 149
M V
Mechanical Noise (Knock) in Engine..................... 61 Valve Rotocoil or Spring Lock Is Free ................... 64
Probable Causes ............................................... 61 Probable Causes ............................................... 64
Recommended Actions...................................... 61 Recommended Actions...................................... 64
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 160/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 161
Index Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 161/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
162 RENR5622
Index Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 162/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
RENR5622 163
Index Section
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 163/164
7/18/2019 CAT 3516 B and 3516 B High Displacement Engines _ Troubleshooting _ CATERPILLAR
http://slidepdf.com/reader/full/cat-3516-b-and-3516-b-high-displacement-engines-troubleshooting-caterpillar 164/164