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MAINTENANCE INTERVALS

Operation and Maintenance Manual Excerpt

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131 Maintenance Section Troubleshooting

Troubleshooting
This topic is intended to provide the owner/operator suggestions for diagnosing minor engine problems. The guidelines are only brief descriptions of common sense remedies which can be performed without extensive knowledge of the engine operation. Refer to the Service Manual for extensive descriptions of problems and instructions for repair. Caterpillar recommends contacting your authorized Caterpillar dealer for major engine problems which require special tools and procedures. Troubleshooting a failure on an engine can be a difficult procedure. For complete troubleshooting information, see the Service Manual for your engine. All repairs should be made by a properly trained mechanic. Your Caterpillar dealer has the personnel and special tools needed to troubleshoot and make repairs to your engine. This list of problems, causes, and corrections will only give an indication of where a possible problem can be, and what repairs may be needed. Remember that a problem is not normally caused only by one part, but by the relation of one part with other parts. Your Caterpillar dealer is equipped with the necessary tools and personnel to provide assistance when necessary. If you have a problem that does not appear in this index, refer to the Service Manual for your engine and/or contact you Caterpillar dealer.

1. Engine will not crank


Batteries: Make sure battery cables are corrosion free and securely attached. Check battery output and charge or replace. Starting Circuit Wiring: Check wiring to starting motor solenoid. Starting Motor Solenoid: Inspect cables for corrosion, 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, plugged fuel tank connections, obstructed or kinked fuel suction lines, plugged fuel filter, air in fuel system or kinked, leaking or broken fuel lines. Fuel Transfer Pump: At cranking speed, the fuel transfer pump should supply fuel to the engine at 20 kPa (3 psi). If fuel pressure is less than 20 kPa (3 psi), replace the fuel filters. Check for air in the fuel system, sticking, binding or defective fuel bypass valve. Check lip-type seal on transfer pump drive shaft. When the engine is fully loaded the transfer pump should supply fuel at 415 to 450 kPa (60 to 65 psi). Engine Timing: See your authorized dealer. Shutoff Solenoid: Solenoid must be energized to shut off the engine. Actuate the control that operates the shutoff solenoid and listen for a clicking sound. If a clicking sound is not present or apparent, remove the solenoid. Try to start the engine again. If the engine starts, the solenoid is defective and must be replaced. Mechanically override the shutoff solenoid by attaching a lever to the fuel pump. Push lever backward to override the solenoid or forward to shut off fuel supply.

Troubleshooting Index
1. Engine will not crank 2. Engine cranks, but will not start 3. Engine starts, but stalls immediately 4. Erratic or unstable engine speed (rpm) 5. Engine misfires or runs rough 6. No or poor response to throttle 7. Low power/Engine speed (rpm) restricted 8. Intermittent engine shutdowns or power reduction 9. Excessive vibration 10. Valve train noise 11. Excessive black or gray smoke 12. Excessive white or blue smoke 13. Low engine oil pressure 14. Excessive lubrication oil consumption 15. Coolant in engine oil 16. Premature engine wear 17. High exhaust temperature 18. Abnormal engine coolant temperature 19. Oil in cooling system 20. Excessive fuel consumption 21. Alternator fails to charge/charging rate high, low or unsteady 22. Alternator noise

3. Engine starts, but stalls immediately


Shutoff Solenoid: Solenoid must be energized to shut off the engine. Actuate the control that operates the shutoff solenoid and listen for a clicking sound. If a clicking sound is not present or apparent, remove the solenoid. Try to start the engine again. If the engine starts, the solenoid is defective and must be replaced.

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