3512 INDUSTRIAL ENGINE OIL WELL SERVICE Caterpillar

Troubleshooting Without A Diagnostic Code

This section is to be used for troubleshooting problems that have symptoms but do not have ACTIVE diagnostic codes. Some engine symptoms are caused by conditions or components other than the electronic control system, such as fuel system problems or improperly adjusted valves.

Before using this section, be sure that you have gathered information about the complaint to adequately describe the symptoms, verified that the complaint is not due to normal engine operation and repaired all ACTIVE Diagnostic Codes. Refer to Section 4: Troubleshooting With A Diagnostic Code.

The basic philosophy of troubleshooting this engine is to follow the three steps listed below FIRST to diagnose a malfunctioning engine:

1. Gather Operator Information. Verify complaint is not due to normal engine operation.

2. Perform a visual inspection. Check fuel and oil level, supply and/or condition. Check for visible wiring and connector problems or damaged components.

3. Check and repair all ACTIVE/LOGGED Diagnostic Codes using the troubleshooting procedures in Section 4: Troubleshooting With A Diagnostic Code.

If ALL three of these inspections reveal no problems, identify probable causes using the procedure or procedures in this section that best describes the symptoms. Narrow the probable causes given in the procedure by considering operator information, operating conditions, and repair history of the machine.

Operator Information

* What happened, and when?

* Under what conditions?

Was the engine rpm (speed) high or low?

Was the engine under load?

* Are there any customer or dealer installed systems that could cause this symptom?

* What else occurred?

* When did the symptoms begin (and what else happened at that time)?

LOGGED Diagnostic Codes

* Do they correlate to probable causes?

* Did they occur at the same time as the symptoms?

* Are some codes Logged repeatedly?

Other Symptoms

* Are they related to this symptom?

* Do they have common probable causes?

Finally, test each probable cause using the tests suggested by the procedure. Be sure to check connectors, especially on intermittent problems! Refer to P-500: Inspecting Electrical Connectors for details.

P-301: Engine Cranks But Will Not Start

Probable root causes:

* Engine speed (rpm) signal

* Engine Shutdown Input

* Air Shutoff Valves

* Fuel Supply

* Rack Controls

* Combustion Problem

Perform the following tests:

1. Engine speed (rpm) signal

Use an Electronic Service Tool to verify the ECM is receiving a correct engine rpm signal. If rpm is erratic or incorrect, refer to P-522: Engine Speed Sensors. If unable to access engine status information, refer to P-310: Electronic Service Tool Will Not communicate With ECM.

2. Engine Shutdown Input

Use an Electronic Service Tool to verify the Shutdown (Run/Stop) Input status is set to RUN.

3. Air Shutoff Valves

Reset if necessary. Refer to Operation & Maintenance Manual and P-534: Air Shutoff Solenoid.

4. Fuel Supply

Verify fuel is present at the fuel return line while cranking. Check for excessive air in fuel. A 9U6872 Flow Sight Tube is helpful in determining the presence of air in fuel. Check fuel quality and for congealed fuel (wax) in temperatures below 0 °C (32 °F).

5. Rack Controls

Verify the rack controls are delivering sufficient cranking rack position. Refer to P-532: Rack Actuation System and P-531: Rack Position Sensor / Calibration.

6. Combustion Problems

Check for combustion problems (mechanical).

P-302: Engine Starts But Stalls Immediately

Probable root causes:

* Air Shutoff Valves

* Low Oil Pressure

* Fuel supply

* Rack controls

* Engine speed (rpm) signal

* Electrical power supply to the ECM

Perform the following tests:

1. Air Shutoff Valves

Check if Air Shutoff Valves are tripping. Refer to P-534: Air Shutoff Solenoid if Air Shutoff Valves are closing.

2. Low Oil Pressure

Use an Electronic Service Tool to monitor oil pressure status while the problem is occurring. Check for a 100-01 Low Oil Pressure Alarm. Also, Check for proper operation of any customer installed engine protection systems.

3. Fuel Supply

Check fuel supply for air in fuel, a plugged fuel supply, or return lines with congealed fuel (wax) in temperatures below 0 °C (32 °F).

4. Rack Controls

Refer to P-532: Rack Actuation System and P-531: Rack Position Sensor / Calibration.

5. Engine speed (rpm) signal

Refer to P-522: Engine Speed Sensors.

6. Electrical power supply to the ECM

Refer to P-501: Electrical Power Supply

P-303: Erratic Or Unstable Engine RPM

Probable root causes:

* Rack Controls

* Throttle Position Sensor

* Engine speed (rpm) signal

* Fuel Supply

* ECM or Personality Module

* Customer Installed Service Tool Connector

Perform the following tests:

1. Rack Controls

Refer to P-532: Rack Actuation System and P-531: Rack Position Sensor / Calibration.

2. Throttle Position Sensor

Refer to P-502: Throttle Sensor.

3. Engine Speed (RPM) Signal

Refer to P-522: Engine Speed Sensors.

4. Fuel Supply

Check fuel supply for air in fuel, a plugged fuel supply, or return lines with congealed fuel (wax) in temperatures below 0 °C (32 °F).

5. ECM or Personality Module

Refer to P-520: ECM/Personality Module.

6. Customer Installed Service Tool Connector

Under certain conditions, an excessively long customer installed Service Tool Connector can pick up electrical noise that can cause unstable engine operation. Temporarily disconnect ATA data link wires at the J31 Customer Connector to determine if this is the cause.

P-304: Poor Or No Response To Throttle

Probable root causes:

* Active diagnostic codes

* Cold Mode (normal operation)

* Throttle position signal

* Rack controls

Perform the following tests:

1. Active diagnostic codes

Troubleshoot any ACTIVE or LOGGED diagnostic codes.

2. Cold Mode

Verify that the ECM is out of cold mode.

3. Throttle position signal

Refer to P-502: Throttle Sensor.

4. Rack Controls

Refer to P-532: Rack Actuation System and P-531: Rack Position Sensor / Calibration.

P-305: Engine Misfires Or Runs Rough

Probable root causes:

* Fuel System

* Valve lash

* Faulty Fuel Injector

* Fuel Timing

* Inlet Air System Problem

* Exhaust Problem

* Unstable Rack Motion

* Cylinder Problem

Perform the following tests:

1. Fuel System

Check fuel quality. Refer to SEBD0717, Diesel Fuel And Your Engine.

Check for excessive air in fuel. A 9U6872 Flow Sight Tube installed in the return line is helpful in determining the presence of air in fuel or a plugged fuel return pressure regulating valve. If excessive air is present in the fuel return line, inspect the suction side of the fuel system for leaks. Repair as necessary. If the problem is not found, install a sight tube in the inlet line to the fuel transfer pump. If excessive air is present in the return line, but not in the inlet line, combustion air may be leaking past an injector.

Check fuel pressure. The fuel transfer pump outlet pressure at both fuel manifolds should be approximately 415 kPa (60 psi) typical at full load speed. If pressure is low, replace fuel filters. If still low, inspect transfer pump, bypass valve and fuel pressure regulator.

2. Valve Lash

Check for popping sounds in air inlet. If present, adjust according to the Systems Operation Testing & Adjusting Manual.

3. Faulty Fuel Injector

Check exhaust manifold port temperatures. Low temperatures at low idle speed may be an indication of no fuel to the cylinder. High temperature can indicate too much fuel.

4. Fuel Timing

Check according to the Systems Operation Testing & Adjusting manual. Adjust as necessary.

5. Inlet Air System Problem

Check for loose ducting connections between the turbocharger and inlet manifold. Check for leakage at the inlet manifold. Check for air system problems: plugged air filter, aftercooler restrictions, aftercooler leaks, high inlet air temperature, etc. Maximum inlet restriction measured at the turbocharger inlet is 6.3 kPa (26 in H₂O). Refer to Systems Operation Testing and Adjusting for details.

6. Exhaust Problem

Check for exhaust system restrictions. Maximum exhaust restriction (after turbocharger) is 6.7 kPa (27 in H₂O). Refer to Systems Operation Testing and Adjusting for details. Check for exhaust leaks at the exhaust manifold and at the turbocharger mounting flange.

7. Unstable Rack Motion

Check for unstable rack motion. Refer to P-303: Erratic Or Unstable Engine RPM.

8. Cylinder Problem

Remove valve covers and inspect for damage.

Inspect inside of suspect cylinders for damage.

Refer to NEHS0504 Tool Operating Manual, Using The 1U5268 And 8T-9290 Inspection Borescopes.

P-306: Low Power/Engine RPM Restricted

Probable root causes:

* Active diagnostic codes

* Factory Parameters (normal operation)

* Throttle position signal

* Inlet manifold (boost) pressure signal

* Rack controls

* Fuel Filter/Fuel supply restrictions

* Fuel Temperature/Quality

* Inlet air system problem

* Exhaust system problem

* Turbocharger defective

* Cylinder Problem

Perform the following tests:

1. Active diagnostic codes

Troubleshoot any ACTIVE or LOGGED diagnostic codes. Check for a 106-01 Low Atmospheric Pressure Derate.

2. Factory Parameters

Verify that the Full Load Setting and Full Torque Settings are programmed to the values on the Engine Information Plate.

3. Throttle position signal

Use an Electronic Service Tool to verify that throttle position reaches 100 percent. Refer to P-502: Throttle Sensor.

4. Inlet Manifold (Boost) Pressure Signal

Check for proper operation of the Boost Pressure Sensor. Refer to P-527: Inlet Manifold (Boost) Pressure Sensor.

5. Rack Controls

Refer to P-530: Dynamic Rack Controls and P-532: Rack Actuation System.

6. Fuel supply restrictions

Check for proper fuel return flow. Check fuel pressure. The fuel transfer pump outlet pressure at both fuel manifolds should be approximately 415 kPa (60 psi) typical at full load speed. If pressure is low, replace fuel filters. If still low, inspect transfer pump, bypass valve and fuel pressure regulator. Refer to Systems Operation Testing and Adjusting for details.

7. Fuel Temperature

If fuel return flow temperature exceeds 82 °C (180 °F), and fuel level is not low, a fuel cooler is recommended to prevent power loss and maintain acceptable injector life. Check fuel quality and API. Refer to SEBD0717, Diesel Fuel And Your Engine.

8. Inlet air system problem

Check for loose ducting connections between the turbocharger and inlet manifold. Check for leakage at the inlet manifold. Check for air system problems: plugged air filter, aftercooler restrictions, aftercooler leaks, high inlet air temperature, etc. Maximum inlet restriction measured at the turbocharger inlet is 6.3 kPa (26 in H₂O). Refer to Systems Operation Testing and Adjusting for details.

9. Exhaust system problem

Check for exhaust system restrictions. Maximum exhaust restriction (after turbocharger) is 6.7 kPa (27 in H₂O). Refer to Systems Operation Testing and Adjusting for details. Check for exhaust leaks at the exhaust manifold and at the turbocharger mounting flange.

10. Turbocharger defective

Inspect the compressor wheel for damage, excessive deposits, etc. Rotate the compressor wheel and check for dragging or binding. Check for excessive play in turbocharger bearings. If a problem is found, determine the source or problem will reoccur. Check wastegate for signs binding.

11. Cylinder Problem

Remove valve covers and inspect for damage. Inspect inside of suspect cylinders for damage. Refer to NEHS0504 Tool Operating Manual, Using The 1U5268 And 8T-9290 Inspection Borescopes.

P-307: Intermittent Engine Shutdowns

Probable root causes:

* Poor Electrical Connections

* Battery power or ground to the ECM

* Aftermarket engine protection devices

* Fuel supply

* Throttle Position Sensor

* Air Shutoff Valves

* Rack controls

* Engine speed (rpm) sensor

Perform the following tests:

1. Poor Electrical Connections

Check the following external ECM wiring harness and connectors: ECM (J14/P14), MUI Interface (J15/P15), Customer (J31/P31), Rack Actuator (J1/P1) and Air Shutoff Solenoid (J33/P33). Refer to P-500: Inspecting Electrical Connectors

2. Battery power or ground to the ECM

Refer to P-501: Electrical Power Supply.

3. Aftermarket engine protection devices

Check for correct installation and operation of engine protection (shutdown) devices.

4. Fuel Supply

Check fuel tanks and lines for foreign objects that may block the fuel supply.

5. Throttle Position Sensor

Refer to P-502: Throttle Sensor.

6. Air Shutoff Valves

Reset if necessary. Refer to Operation & Maintenance Manual and P-534: Air Shutoff Solenoid.

7. Rack controls

Refer to P-532: Rack Actuation System and P-531: Rack Position Sensor / Calibration.

8. Engine speed (rpm) sensor

Refer to P-522: Engine Speed (RPM) Sensors.

P-308: Intermittent Engine RPM Or Power Cutouts

Probable root causes:

* Poor electrical connections

* Battery power or ground to the ECM

* Aftermarket engine protection devices

* Fuel Supply

* Throttle position signal

* Rack controls

Perform the following tests:

1. Poor Electrical Connections

Check the following external ECM wiring harness and connectors: ECM (J14/P14), MUI Interface (J15/P15), Customer (J31/P31), Rack Actuator (J1/P1) and Air Shutoff Solenoid (J33/P33). Refer to P-500: Inspecting Electrical Connectors.

1. Battery power or ground to the ECM

Refer to P-501: Electrical Power Supply.

2. Aftermarket engine protection devices

Check for correct installation and operation of engine protection (shutdown) devices.

3. Fuel Supply

Check fuel tanks and lines for foreign objects that may block the fuel supply.

4. Throttle position signal

Refer to P-502: Throttle Sensor.

5. Rack controls

Refer to P-532: Rack Solenoid (BTM) and P-531: Rack Position Sensor/Calibration.

P-309: Diagnostic Lamp Is Malfunctioning

Probable root causes:

* Intermittent diagnostic codes

* Lamp circuit problem

Perform the following tests:

1. Check for logged diagnostic codes.

2. Refer to P-505: Alarm Lamps.

P-310: Electronic Service Tool Will Not Communicate With The ECM

Probable root causes:

* Electrical power supply to the ECM

* Connector or wiring problem in the ECM wiring harness

* Electronic service tool cable problem

* Incorrect Electronic Service Tool Software

* ECM or Personality Module

Perform the following tests:

1. Electrical power supply to the ECM

Refer to P-501: Electrical Power Supply.

2. Connector or wiring problem in the ECM wiring harness

Inspect Electronic Service Tool Connector J13, ECM Connector J14/P14, and wiring. Refer to P-500: Inspecting Electrical Connectors. Verify that battery voltage is present between pin-A and pin-B of J13. Use an ohmmeter to check for opens or shorts in the data link connections between J13 and ECM Connector P14. Refer to Electrical System Schematic.

3. Electronic service tool cable problem

Verify the correct service tool cable is connected to service tool connector J13. Check service tool and cable operation on another engine, if possible.

4. Incorrect Electronic Service Tool Software

Verify the correct Service Program Module (SPM) is installed in the ECAP or Communication Adapter.

5. ECM or Personality Module

Ensure the correct Personality Module is installed and properly seated. Refer to P-520: ECM/Personality Module.

P-311: ECM Will Not Accept Factory Passwords

Probable root causes:

* Incorrect screen

* Error entering password

* Incorrect Serial Number (Engine, ECM, or Electronic Service Tool), Total Tattletale, or Reason Code used to obtain password

Perform the following tests in order:

1. Verify that the electronic service tool is on the Factory Passwords Screen and expects factory passwords (rather than Customer Passwords).

2. Verify correct passwords were entered. Check each character in passwords for accuracy (for instance letter I vs. number 1, Z vs. 2, O vs. 0, etc). Turn the Engine Control Switch to the OFF/RESET position for 30 seconds and then retry.

3. Verify the Electronic Service Tool is on the Factory Passwords screen. Verify Engine serial number used to calculate password is correct. Verify the Total Tattletale, Reason Code, Electronic Service Tool Serial Number and ECM Serial Number is correct. Refer to Factory Passwords in Section 2: Programming Parameters for more details.