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2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt

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131Maintenance Section

Troubleshooting

Troubleshooting

This topic is intended to provide the owner/operatorsuggestions for diagnosing minor engine problems.The guidelines are only brief descriptions ofcommon sense remedies which can be performedwithout extensive knowledge of the engineoperation.

Refer to the Service Manual for extensivedescriptions of problems and instructions for repair.Caterpillar recommends contacting your authorizedCaterpillar dealer for major engine problems whichrequire special tools and procedures.

Troubleshooting a failure on an engine can be adifficult procedure. For complete troubleshootinginformation, see the Service Manual for your engine.

All repairs should be made by a properly trained

mechanic. Your Caterpillar dealer has thepersonnel and special tools needed to troubleshootand make repairs to your engine.

This list of problems, causes, and corrections willonly give an indication of where a possible problemcan be, and what repairs may be needed.Remember that a problem is not normally causedonly by one part, but by the relation of one part withother parts.

Your Caterpillar dealer is equipped with thenecessary tools and personnel to provideassistance when necessary.

Troubleshooting Index

1. Engine will not crank2. Engine cranks, but will not start3. Engine starts, but stalls immediately4. Erratic or unstable engine speed (rpm)5. Engine misfires or runs rough6. No or poor response to throttle7. Low power/Engine speed (rpm) restricted8. Intermittent engine shutdowns or power reduction9. Excessive vibration10. Valve train noise11. Excessive black or gray smoke12. Excessive white or blue smoke13. Low engine oil pressure14. Excessive lubrication oil consumption15. Coolant in engine oil16. Premature engine wear17. High exhaust temperature18. Abnormal engine coolant temperature19. Oil in cooling system20. Excessive fuel consumption21. Alternator fails to charge/charging rate high,

low or unsteady22. Alternator noise

If you have a problem that does not appear in this

index, refer to the Service Manual for your engineand/or contact you Caterpillar dealer.

1. Engine will not crank

Batteries:Make sure battery cables are corrosionfree and securely attached. Check battery output andcharge or replace.

Starting Circuit Wiring:Check wiring to startingmotor solenoid.

Starting Motor Solenoid:Inspect cables forcorrosion, damage or loose connections.

Starting Motor:Test solenoid and motor

operation.

2. Engine cranks, but will not start

Fuel Supply:Check for empty fuel tank, pluggedfuel tank connections, obstructed or kinked fuelsuction lines, plugged fuel filter, air in fuel system orkinked, leaking or broken fuel lines.

Fuel Transfer Pump:At cranking speed, the fueltransfer pump should supply fuel to the engine at 20kPa (3 psi). If fuel pressure is less than 20 kPa (3 psi),replace the fuel filters. Check for air in the fuelsystem, sticking, binding or defective fuel bypass

valve. Check lip-type seal on transfer pump driveshaft. When the engine is fully loaded the transferpump should supply fuel at 415 to 450 kPa (60 to 65psi).

Engine Timing:See your authorized dealer.

Shutoff Solenoid:Solenoid must be energized toshut off the engine. Actuate the control that operatesthe shutoff solenoid and listen for a clicking sound. Ifa clicking sound is not present or apparent, removethe solenoid. Try to start the engine again. If theengine starts, the solenoid is defective and must bereplaced.

Mechanically override the shutoff solenoid byattaching a lever to the fuel pump. Push leverbackward to override the solenoid or forward to shutoff fuel supply.

3. Engine starts, but stalls immediately

Shutoff Solenoid:Solenoid must be energized toshut off the engine. Actuate the control that operatesthe shutoff solenoid and listen for a clicking sound. Ifa clicking sound is not present or apparent, removethe solenoid. Try to start the engine again. If theengine starts, the solenoid is defective and must bereplaced.

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