Troubleshooting C4 4 Marine Generator Set

TROUBLESHOOTING C4.
4 MARINE GENERATOR
SET
Index Troubleshooting C4.4 Marine Generator Set
001- Oil Contains Fuel
002- Oil Contains Coolant
003- Oil Consumption Is Excessive
004- Intake Manifold Air Temperature Is High
005- Intake Manifold Air Pressure Is Low
006- Inlet Air Temperature Is High
007- Fuel Temperature Is High
008- Fuel Rail Pressure Problem
009- Fuel Filter Is Restricted - Secondary Fuel Filter
010- Fuel Filter Is Restricted - Primary Fuel Filter
011- Fuel Consumption Is Excessive
012- Exhaust Temperature Is High
013- Exhaust Has Excessive White Smoke
014- Exhaust Has Excessive Black Smoke
015- Engine Vibration Is Excessive
016- Engine Top Speed Is Not Obtained
017- Engine Shutdown Occurs Intermittently
018- Engine Overspeed
019- Engine Misfires, Runs Rough or Is Unstable
020- Engine Has Mechanical Noise (Knock)
021- Engine Has Early Wear
022- Engine Does Not Crank
023- Engine Cranks but Does Not Start
024- Electronic Service Tool Does Not Communicate
025- ECM Will Not Accept Factory Passwords
026- ECM Does Not Communicate with Other Modules
027- Cylinder Is Noisy
028- Crankcase Fumes Disposal Tube Has Oil Draining
029- Crankcase Breather Ejects Oil
030- Coolant Temperature Is High
031- Coolant Pressure Is High
032- Coolant Level Is Low
033- Coolant Contains Oil
034- Battery Problem
035- Alternator Problem
036- Alternator Is Noisy
Troubleshooting C4.4 Marine Generator Set-Oil Contains Fuel
001- Oil Contains Fuel
Measuring Fuel Dilution

Diesel fuel is chemically similar to the lubricants that are used in diesel engines. A slow fuel leak will
blend the fuel into the oil. Normal operating temperatures may cause volatile parts of the fuel to
vaporize. The fuel that remains in the oil is less volatile.
A closed cup flash test can be performed in order to detect fuel dilution. The flash test is designed to
measure the volatile parts of the fuel that are remaining in the oil. Detecting less volatile fuel is difficult.
The lack of volatility reduces the accuracy of the flash test.
Since the flash test does not accurately detect fuel dilution, do not use the flash test as the only
measure of fuel dilution. Instead, verify the dilution by the following methods:
 Gas chromatograph fuel dilution test

 Oil viscosity
The test that uses a gas chromatograph is designed to measure fuel dilution in crankcase oils. The gas
chromatograph can identify the small chemical differences between diesel fuel and lubricating oil. A gas
chromatograph is used to measure fuel dilution at all Caterpillar regional SOS laboratories. Some Cat
dealers also use a gas chromatograph. Even though the gas chromatograph provides a more accurate
measure of fuel dilution, always verify the results with the viscosity test.
A significant level of fuel dilution reduces oil viscosity. If an unacceptable level of fuel dilution is
suspected, the kinematic viscosity of the oil must be measured.
Fuel dilution that is greater than 4 percent will usually cause viscosity that is less than the specified
viscosity grade. If the oil is still within the specified viscosity grade, fuel dilution is unlikely to have
reached an unacceptable level. Use the following chart to determine if viscosity has reached the minimum
acceptable level. The guidelines of viscosity in the chart are slightly less than the limits of the SAE
viscosity grades. However, these guidelines still provide adequate engine protection.
Table 1
Minimum Oil Viscosity at 100 °C with Fuel Dilution

Viscosity
Greater Than 4% as Measured by a Gas Action
Grade
Chromatograph
0W-40
5W-40
12.0 cSt
10W-40 Investigate the cause of fuel dilution
15W-40 or reduce the engine oil change
0W-30 interval.
5W-30 9.0 cSt
10W-30
Verifying Fuel Dilution

Always verify fuel dilution by the combination of a viscosity test and a gas chromatograph test that gives a
result in excess of 4 percent. If a fuel dilution test cannot be performed locally, submit an oil sample to a
Cat dealer for analysis.
Probable Causes
 Fuel injector seals

 Fuel injector tip
Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 2
Troubleshooting Test Steps Values Results
Result: Injector seals are damaged.

1. Fuel Injector Seals
Fuel
Replace any damaged injector seals.
injector
A. Check for signs of damage to the
seals
seals for the fuel injectors. Result: All injector seals are OK.

Proceed to Test Step 2.
Result: A fuel injector is damaged.
Replace the fuel injector. Refer to Disassembly and

2. Fuel Injector Tip
Assembly, "Electronic Unit Injector - Remove" and
Fuel
Disassembly and Assembly, "Electronic Unit Injector -
A. Check for signs of damage to the injector
Install".
fuel injectors. Check the fuel injector tip
tip for cracks or breakage.
Result: All fuel injectors are OK.

Contact the Technical Communicator at a Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Oil Contains Coolant

002- Oil Contains Coolant
Probable Causes
 Engine oil cooler

 Cylinder head gasket
 Cylinder head
 Cylinder block
Recommended Actions
Table 1
Result: Evidence of coolant in the oil

system is identified.
Install a new oil cooler. Refer to

1. Engine Oil Cooler Disassembly and Assembly, "Engine Oil
Cooler - Remove" and Disassembly and
A. Drain the engine lubricating oil and coolant Oil cooler Assembly, "Engine Oil Cooler - Install" for
from the engine. Check for leaks in the oil cooler the correct procedure.
assembly.
Result: No evidence of coolant in the oil
system is found.

2. Cylinder Head Gasket Cylinder Result: The cylinder head gasket is faulty

or shows signs of leakage.
A. Remove the cylinder head. Refer to
Install a new cylinder head gasket.
Disassembly and Assembly, "Cylinder Head - head
Remove" for the correct procedure. Inspect the gasket
Result: The cylinder head gasket is OK.
cylinder head gasket for faults and any signs of
leakage.

Result: The cylinder head is not within

specification for flatness.
3. Cylinder Head
Install a new cylinder head. Refer to
Disassembly and Assembly, "Cylinder Head
A. Check the cylinder head for flatness. Refer to
- Install" for the correct procedure.
Systems Operation, Testing, and Adjusting,
"Cylinder Head - Inspect" for the correct
Result: The cylinder head shows signs of a
procedure.
fault or leakage.
B. Check the mating face of the cylinder head for
Cylinder Install a new cylinder head. Refer to
faults and signs of leakage. If a fault is found,
head Disassembly and Assembly, "Cylinder Head
replace the cylinder head. If signs of leakage are
- Install" for the correct procedure.
found, determine the cause of the leakage. Refer
to Systems Operation, Testing, and Adjusting,
Result: An internal core plug in the
"Cylinder Head - Inspect" for the correct
cylinder head shows signs of leakage.
procedure.
Replace the faulty core plug.
C. Check the internal core plugs in the cylinder
head for signs of leakage.
Result: The cylinder head is OK.


4. Cylinder Block Cylinder Result: The top face of the cylinder block

block has a fault.
A. Inspect the top face of the cylinder block for
faults and signs of leakage. Replace the cylinder block.

Result: The top face of the cylinder block
shows signs of leakage.
Determine the cause of the leakage. Refer

to Systems Operation, Testing, and
Adjusting, "Cylinder Block - Inspect" for
the correct procedure.
Result: The cylinder block is OK.
Install the cylinder head. Refer to

Disassembly and Assembly, "Cylinder Head
- Install".
Remove the oil filter element. Install a

new engine oil filter element. Fill the
engine with clean engine oil to the correct
level. Refer to the Operation and
Maintenance Manual, "Engine Oil and Filter
- Change" for more information.
Fill the cooling system. Refer to the

Operation and Maintenance Manual for
more information.
Contact the Technical Communicator at a

Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Oil Consumption Is Excessive

003- Oil Consumption Is Excessive
Probable Causes
 Misreading oil level

 Oil leaks
 Engine crankcase breather
 Oil level
 Air intake and exhaust system
 Turbocharger
 Low compression (cylinder pressure)
Recommended Actions
Table 1
Result: The oil consumption is less than

0.08% of the fuel consumption.
1. Misreading Oil Level Oil consumption is within specification.

Return the unit to service
Oil level
A. Accurately measure the consumption of oil

and fuel over a period of 50 engine hours. Result: The oil consumption is greater
than 0.08% of the fuel consumption.

Result: An oil leak is identified.
Rectify the cause of the oil leak.

2. Oil Leaks
Result: Oil is present in the coolant.
A. Check for evidence of oil leaks on the
Oil leaks
engine. Refer to Troubleshooting, "Coolant

Contains Oil".
B. Check for evidence of oil in the coolant.
No oil leaks are identified

3. Engine Crankcase Breather Breather Result: The engine crankcase breather

is blocked or restricted.
A. Check the engine crankcase breather for
blockage or restrictions. Clear the blockage or restriction.
Result: Excessive oil is ejected from
the outlet of the breather.
Investigate the cause of the excessive

oil content in the breather flow. If
B. Check for excessive oil from the outlet of equipped, replace the filter in the
the breather. breather.

Result: No oil is ejected through the
breather.

Result: The oil level in the engine is

high.
Make sure that the oil is not

contaminated with fuel. Refer to
Troubleshooting, "Oil Contains Fuel".
4. Oil Level Make sure that the oil is not

Oil level contaminated with coolant. Refer to
A. Check for a high oil level in the engine. Troubleshooting, "Oil Contains
Coolant".
Remove the excess oil.
Result: The oil level is OK.

Result: The air filter restriction

indicator has operated or the air filter
is blocked.
5. Air Intake and Exhaust System Make sure that the air filter is clean
and serviceable. If necessary, replace
A. Check the air filter restriction indicator, if the air filter.
equipped.
Result: The air intake or the exhaust
Air intake and
Check the air intake and the exhaust system system is blocked, restricted, or
exhaust system
for the following defects: damaged.

· Blockages Repair the air intake or the exhaust
· Restrictions system, as required.
· Damage to the air intake and exhaust lines
and hose Result: The air intake or the exhaust
system is OK.

6. Turbocharger Turbocharger Result: The oil drain for the

turbocharger is blocked or restricted.
Note: The turbocharger that is installed on
this engine is a nonserviceable item. If any Remove the blockage or restriction. If
mechanical fault exists, then the turbocharger necessary, replace the oil drain line.
must be replaced. Result: The turbocharger has an
internal oil leak.
A. Check that the oil drain for the
turbocharger is not blocked or restricted. Replace the turbocharger.
B. Check the turbocharger for evidence of an Result: The turbocharger is OK.

internal oil leak.

Result: The results of the compression

test are outside the specifications.
Investigate the cause and rectify any

faults.
Note: Possible causes of low

compression are shown in the following
list:
7. Low Compression (Cylinder Pressure)
· Loose glow plugs
Cylinder
A. Perform a compression test. Refer to · Faulty piston
compression
Systems Operation, Testing, and Adjusting, · Faulty piston rings

"Compression - Test ". · Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

test are OK.
Contact the Technical Communicator at

a Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Intake Manifold Air

Temperature Is High
004- Intake Manifold Air Temperature Is High
The Electronic Control Module (ECM) monitors the intake manifold air for excessive temperature. The
following codes are associated with high intake manifold air temperature:
Table 1
Diagnostic Codes for High Intake Manifold Air Temperature
J1939
Code Description Comments
Code
The engine has been running for 3 minutes.

No other 105 codes are active.
168 codes are not active.
Engine Intake Manifold #1
The intake manifold air temperature exceeds the value that
105-15 Temperature : High - least severe
is programmed into the ECM for 8 seconds. The code is
(1)
logged.
This code will be reset when the temperature is less than
123° C (253° F) for 4 seconds.
105-16 Engine Intake Manifold #1 The engine has been running for 3 minutes.
Temperature : High - Moderate No other 105 codes are active.
168 codes are not active.
The intake manifold air temperature exceeds the value that
is programmed into the ECM for 8 seconds. The engine will
Severity (2)
be derated. The code is logged.
This code will be reset when the temperature is less than
125° C (257° F) for 20 seconds.
Probable Causes
 Coolant level
 Cooling fan (if applicable)
 Air inlet and exhaust system
 Ambient temperature
 Running condition
Recommended Actions
Table 2
Result: The coolant level is

low.
1. Coolant Level Fill the coolant system to the

correct level. Refer to the
A. Check that the coolant is filled to the correct level. Operation and Maintenance
Coolant Manual, "Coolant Level -
Note: If the coolant level is too low, air will get into the Check".
cooling system. Air in the cooling system will cause a
reduction in coolant flow. Result: The coolant level is
OK.

Result: The cooling fan is

damaged.
2. Cooling Fan (If Applicable)
Repair or replace the cooling
A. Check the cooling fan for damage.
Cooling fan fan.

Note: A damaged fan t can result in insufficient airflow
Result: The cooling fan is OK.
over the engine.


3. Air Intake and Exhaust System Air intake and Result: The air intake or
exhaust exhaust system is blocked,
A. Check the air intake and exhaust system for the restricted, damaged, or loose.
following defects:
Make all necessary repairs to
· Blockages the air intake system.
· Restrictions
· Damage to the air intake ducts and hoses Result: The air intake and
· Loose connections and air leaks exhaust system is OK.

For applications with a raw
water cooling system or a keel
cooled cooling system,
proceed to Test Step 4.
For applications with a

radiator cooling system,

Result: The heat exchanger

was obstructed.
4. Check for an Obstructed Heat Exchanger
Clear any obstructions. Return
A. The intake manifold air temperature can increase if
Obstructed the unit to service.
the flow through the heat exchanger is obstructed. Check
heat exchanger
the heat exchanger for obstructions or debris. Ensure
Result: The heat exchanger
that the flow of coolant through the heat exchanger is
was not obstructed.
adequate.


Result: The sea water pump is

obstructed.

the unit to service.
5. Check the Flow Through the Sea Water Pump Result: The flow from the sea
water pump is reduced.
A. The intake manifold air temperature can increase if Obstructed sea
the flow from the sea water pump is reduced. Ensure water pump Repair the sea water pump or
that the flow of water through the sea water pump is replace the sea water pump.
adequate.
Result: The output from the
sea water pump is sufficient.
Contact the Technical

Communicator at a Cat
dealer.

Result: The ATAAC was

obstructed.
6. Check for an Obstructed ATAAC
A. The intake manifold air temperature can increase if Obstructed the unit to service.
the flow through the ATAAC is obstructed. Check the heat exchanger
ATAAC for obstructions or debris. Ensure that the flow of Result: The ATAAC was not
air through the ATAAC is adequate. obstructed.


7. Ambient Temperature Ambient Result: The ambient air

Temperature temperature is high.
A. Check for a high ambient temperature.
Operate the engine at
Note: When outside temperatures are too high, there is reduced speed or reduced
power.
insufficient temperature difference between the outside Result: The ambient air

air and the intake air. temperature is OK.


Result: The engine is
8. Running Condition operating in the lug condition.
A. Check that the engine is not operating in the lug Reduce the load on the engine
condition. or, if possible, increase the
power rating of the engine.
Running
Note: When the load that is applied to the engine is too
condition
large, the engine will run in the lug condition. When the Result: The engine is not

engine is running in the lug condition, engine rpm does operating in the lug condition.
not increase with an increase of fuel. This lower engine
rpm causes a reduction in coolant flow through the Contact the Technical
system. Communicator at a Cat
dealer.

Troubleshooting C4.4 Marine Generator Set-Intake Manifold Air Pressure Is

Low
005- Intake Manifold Air Pressure Is Low
The Electronic Control Module (ECM) monitors the intake manifold air pressure. The following code is
associated with low intake manifold air pressure:
Table 1
Code for Low Intake Manifold Air Pressure
J1939
Code
Engine Intake Manifold #1 This pressure is a variable value that is calculated by the
102-18 Pressure : Low - moderate ECM. The resulting value is dependent on the operating
severity conditions of the engine.
Probable Causes
 Intake air filter

 Air intake system
 Turbocharger
Recommended Actions
Table 2
1. Intake Air Filter Air filter Result: The air filter is blocked.

A. Ensure that the air filter is clean and Replace the air filter element. Refer to the
serviceable. Operation and Maintenance Manual,
"Engine Air Cleaner Element - Replace".
Result: The air filter is OK.


2. Air Intake System Result: The air intake system is blocked,

restricted, damaged, or loose.
A. Check the air intake system for the
following defects: Make all necessary repairs to the air intake
Air intake system.
· Blockages
· Restrictions Result: The air intake system is OK.
· Damage to the air intake ducts and hoses
· Loose connections and air leaks Proceed to Test Step 3.

3. Turbocharger
Result: There is a fault with the
Note: The turbocharger that is installed on
turbocharger.
the engine is a no serviceable item. If any
mechanical fault exists, then the turbocharger
Replace the turbocharger. Refer to
must be replaced.
Disassembly and Assembly, "Turbocharger -
Remove" and Disassembly and Assembly,
A. Check that the compressor housing for the Turbocharger
"Turbocharger - Install".
turbocharger is free of dirt and debris.
Result: The turbocharger is OK.
B. Check that the turbine housing for the
turbocharger is free of dirt and debris.
Cat dealer.
C. Check that the turbine blades rotate freely

in the turbocharger.

Troubleshooting C4.4 Marine Generator Set-Inlet Air Temperature Is High

006- Inlet Air Temperature Is High
Use this procedure to determine the cause of high air inlet temperature.
Probable Causes
 Diagnostic codes
 High ambient air temperature
 Intake air restriction and/or high altitude
 Intake air from a heated area
Recommended Actions
Table 1
1. Diagnostic Codes Diagnostic Result: There are active or

codes logged codes.
A. Establish communication between the electronic
service tool and the Electronic Control Module (ECM).
Refer to Troubleshooting, "Electronic Service Tools", if Troubleshoot any codes before
necessary. continuing with this
procedure.
B. Download the "Warranty Report" from the engine ECM

before performing any troubleshooting or clearing Result: There are no active or
diagnostic trouble codes. logged codes.
Troubleshoot any active codes before continuing with this Proceed to Test Step 2.
procedure.

Result: The ambient air

temperature is not within the
design specifications.
When possible, modify the

cooling system and the air
charge cooler in order to make
2. High Ambient Air Temperature the system suitable for local
conditions.
Ambient Air
A. Determine if the ambient air temperature is within the
temperature
design specifications for the cooling system and the air Result: The ambient air

charge cooler. temperature is within the
design specifications.
Operate the engine at a

reduced load or operate the
engine at a reduced speed.

Result: There is a suspected
intake air restriction.
Check for blocked air filters.

Check for obstructions in the
3. Intake Air Restriction and/or High Altitude air intake.
Replace the air filters or

A. Measure the intake manifold pressure while the engine remove the obstruction from
is operating under load. For specific data, refer to the the air intake.
Technical Marketing Information (TMI) for the engine.
Intake air
Result: High altitude operation
problem
Note: Low air pressure at the air intake for the is suspected of causing the

turbocharger can be caused by a restriction in the air symptom.
intake or a high altitude. When the pressure of the intake
air is low, the turbocharger works harder in order to Make sure that the settings for
achieve the desired intake manifold pressure. This the engine are correct for the
increases intake air temperature. altitude.

Result: There are no air
restrictions or altitude issues.

4. Intake Air from a Heated Area Intake air Result: The intake air is from
a heated area.
If necessary, relocate the air

supply to the intake manifold
to the outside of the engine
enclosure.
Check for air leaks in the pipe

A. Ensure that the air inlet system is not receiving air temperature between the air inlet and the
from a heated area. inlet to the turbocharger
compressor.
Result: The intake air is not

from a heated area.

Communicator at a Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Fuel Temperature Is High

007- Fuel Temperature Is High
This procedure covers the following diagnostic codes:
Table 1
Diagnostic Trouble Codes for High Fuel Temperature
J1939
Code
The temperature of the low-pressure fuel in the high-

pressure fuel pump is high.
The ECM has been powered for at least 2 seconds.
The engine has been operating for at least 185

Engine Fuel Temperature 1 : High - seconds.
174-15
least severe (1)
There are no other faults in the electrical system.
The warning lamp will come on.
The warning lamp will go off when the temperature

drops below the trip point.
174-16 Engine Fuel Temperature 1 : High - The temperature of the low-pressure fuel in the high-
moderate severity (2) pressure fuel pump is high.
The engine has been operating for at least 185

seconds.
There are no other faults in the electrical system.
The warning lamp will come on.

The engine may be derated by 20%.
The warning lamp will go off when the temperature

drops below the trip point for 15 seconds.
Probable causes
 Incorrect position of fuel shut-off valves

 Fuel level in tank
 Return fuel cooler (if equipped)
 Return fuel lines
 Location of the fuel tank
Recommended Actions
Note: Complete the procedure in the order in which the steps are listed.
Table 2
1. Incorrect Position of Fuel Shut-off Valves Result: A fuel valve is closed or not
fully open.
A. Make sure that any fuel shut-off valves in the
feed lines between the fuel tank and the engine Move the valve to the fully open
Valve
are open. position.
positions

B. Make sure that any fuel shut-off valves in the Result: All fuel valves are fully open.
return lines between the engine and the fuel tank
are open. Proceed to Test Step 2.

Result: The fuel level in the tank is low.

2. Fuel Level in Tank
Replenish the fuel tank at the earliest
opportunity.
Note: If the level in the fuel tank is low, the hot
return fuel can raise the temperature in the fuel Fuel level
Result: The fuel level in the tank is
tank.
sufficient to prevent excessive fuel
heating.
A. Check the fuel level in the fuel tank.


3. Return Fuel Cooler (If Equipped) Fuel cooler Result: The fins on the return fuel
cooler are blocked with dirt or debris.
A. Check the fins on the return fuel cooler for
blockage with dirt or debris. Check for fins that are Clean the return fuel cooler.
bent or missing.
Result The fins on the return fuel cooler
are bent or missing.
Repair or replace the return fuel cooler.
Result The return fuel cooler is OK.

Result: The return fuel lines are

blocked or restricted.
4. Return Fuel Lines
Clear the blockage or restriction. If
Return fuel
necessary, replace the return fuel line.
A. Check the return fuel lines for blockage or lines
restrictions.
Result The return fuel lines are clear.


Result: The fuel tank is close to a heat

source.
Shield the fuel tank from the heat

5. Location of the Fuel Tank source or relocate the fuel tank to a
Tank cooler location.
A. Make sure that the fuel tank is not close to a location
heat source. Result The fuel tank is not close to a
heat source.

a Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Fuel Rail Pressure Problem

008- Fuel Rail Pressure Problem
Use this procedure in order to troubleshoot abnormal fuel rail pressure or use this procedure if any of the
following diagnostic trouble codes are active. Refer to Troubleshooting, "Diagnostic Trouble Codes" for
information about the codes.
Table 1
Diagnostic Trouble Codes for Fuel Rail Pressure Problem
J1939
Code
157-16 Engine Injector Metering Rail #1 No other 157-XX codes are active.
Pressure: High - moderate severity (2) 3509-XX codes are not active.
No codes for the high-pressure fuel pump or the
injectors are active.
The fuel rail pressure is above an acceptable level.
The code is logged.
Engine power is derated.
No other 157-XX codes are active.

3509-XX codes are not active.
No codes for the high-pressure fuel pump or the
Engine Injector Metering Rail #1
157-18 injectors are active.
Pressure: Low - moderate severity (2)
The fuel rail pressure is below an acceptable level.
The code is logged.
Engine power is derated.

There is a probable fuel leak from the high-pressure
1239-31 Engine Fuel Leakage 1 fuel system. The amount of leakage is a calculated
parameter.
The code is logged.
The engine may shut down.

High Pressure Common Rail Fuel
5571-0 The pressure limiting valve in the fuel rail is open. This
Pressure Relief Valve : Active
code is a calculated parameter.
The code is logged.
Probable Causes
 Electrical connectors
 Fuel filters
 Fuel rail pressure sensor
 High fuel rail pressure
 Low fuel rail pressure
Recommended Actions
Table 2
1. Diagnostic Codes Diagnostic Result: A 157-16 or 157-18 code is present.

codes
A. Connect the electronic service Proceed to Test Step 2.
tool to the diagnostic connector.
Refer to Troubleshooting, Result: A code other than157-16 or 157-18 is present.
"Electronic Service Tools", if
necessary. Troubleshoot the code. Refer to the proper
troubleshooting procedure.
B. Determine if a diagnostic is
active or recently logged.

Result: There are suspect connectors.

2. Electrical Connectors
Use the electronic service tool to perform the "Wiggle
A. Check for the correct Test".
installation of the ECM J1/P1 and
Connectors
the J2/P2 connectors. Check for Repair or replace connectors that are suspect.

correct installation of the
connector on the fuel rail Result: There are no suspect connectors.
pressure sensor.

Result: The filters have been replaced and the fault is

3. Fuel Filters eliminated.
A. Replace the primary fuel filter Return the unit to service.

and the secondary fuel filters. Fuel filters
Refer to the Operation and Result: The filters have been replaced and the fault is
Maintenance Manual for further still present.
information.

Result: The "Fuel Rail Pressure (absolute)" is more than

5,000 kPa (725 psi).
Test the fuel rail pressure sensor. Refer to

Troubleshooting, "Sensor Signal (Analog, Active) - Test".
Use the electronic service tool in order to perform the

"Fuel Rail Pressure Test". If the test fails, replace the
fuel rail. Refer to Disassembly and Assembly, "Fuel
Manifold (Rail) - Remove and Install".
4. Fuel Rail Pressure Sensor
Confirm that the fault has been eliminated.
A. Make sure that the engine has
Pressure
been shut down for at least 10
sensor Result: The "Fuel Rail Pressure (absolute)" is less than
minutes. Use the electronic
5,000 kPa (725 psi).
service tool to check the status of
the "Fuel Rail Pressure"
Use the electronic service tool in order to perform the

"Fuel Rail Pressure Test". If the test fails, replace the
fuel rail. Refer to Disassembly and Assembly, "Fuel
Manifold (Rail) - Remove and Install".
If the fault is still present and the fuel rail pressure is

high, proceed to Test Step 5.
If the fault is still present and the fuel rail pressure is

low, proceed to Test Step 9.

Result: The Fuel Rail Pressure Test fails.
Replace the SCV and solenoid. Refer to Disassembly and

Assembly, "Fuel Pump Solenoid - Remove and Install".
If the replacement SCV does not eliminate the fault,

turn the isolator switch to the OFF position and
disconnect the electrical connector from the EFLP.
With the isolator switch in the ON position, measure the

voltage at the harness connector for the EFLP. The
voltage must be between 10 VDC and 14 VDC for a 12
5. High Fuel Rail Pressure VDC system. The voltage must be between 20 VDC and
28 VDC for a 24 VDC system. If the voltage is below 10
High fuel rail
A. Use the electronic service tool VDC for a 12 VDC system, investigate the cause. If the
pressure
in order to perform the Fuel Rail voltage is below 20 VDC for a 24 VDC system, investigate

Pressure Test. the cause. Refer to Troubleshooting, "Fuel Pump Relay
Circuit - Test"
Turn the isolator switch to the OFF position and then

reconnect the electrical connector to the EFLP.
If a repair has been performed to rectify a low supply

voltage to the EFLP, attempt to start the engine. If the
engine does not start, proceed to Test Step 6.
Result: The fuel system is OK.

View Image
Table 3
6. Transfer Pump Inlet Regulator (TPIR) Flow Test TPIR flow Result: The fuel flow is
rate greater than the minimum
Refer to Illustration 6. limit.
A. Disconnect the TPIR return line from the drain port on the Proceed to Test Step 9.
TPIR. Install a suitable blanking cap on the open port in the TPIR
return line. Result: The fuel flow is
less than the minimum
B. Connect a temporary drain line to the drain port on the TPIR. limit.
C. Place the end of the temporary drain line into a suitable Proceed to Test Step 7.
calibrated container.
D. With the isolator switch in the ON position but the engine not
running, use a suitable multimeter to measure the input voltage
to the EFLP. Record the reading.
E. With the isolator switch in the ON position but the engine not
running, measure the fuel flow from the temporary drain line.
F. For a 12 VDC system, refer to Illustration 7 for the minimum

acceptable flow rate.
G. For a 24 VDC system, refer to Illustration 8 for the minimum

H. Remove the temporary drain line from the drain port on the
TPIR. Connect the TPIR return line to the TPIR.

Table 4
7. Return Pressure Relief Valve Test PRV test Result: The fuel flow is more than 5% below the
acceptable limit.
A. Disconnect the return line from the
secondary fuel filter base and install a Replace the EFLP.
blank on the line. Install a temporary line
and a calibrated container to the filter Result: The fuel flow is more than 5% above the
base. acceptable limit.
B. With the isolator switch in the ON Contact the Technical Communicator at a Cat
position, measure fuel flow from the dealer.
temporary line.
Result: The fuel flow is within the acceptable
C. If the fuel flow is more than limit.
300 mL/min (10.2 oz/min), replace the
secondary fuel filter base. Refer to Proceed to Test Step 8.
Disassembly and Assembly, "Fuel Filter
Base - Remove and Install (Twin
Secondary Fuel Filter)".
D. Remove the temporary line and

reconnect the return line.
E. If the secondary fuel filter base has

been replaced, attempt to start the
engine. If the engine does not start, use
the following procedure to check the fuel
flow from the EFLP:
F. Disconnect the fuel inlet from the

primary fuel filter. Place the open end of
the disconnected line into a calibrated
container.
G. With the isolator switch in the ON
position, measure the flow from the fuel
line. Refer to the Illustration 4 for the
minimum acceptable fuel flow on a 12
VDC system. Refer to the Illustration 5 for
the minimum acceptable fuel flow on a
24 VDC system.

Result: The TPIR return line or the fuel lines

between the EFLP and the TPIR are blocked or
8. Check the Return Fuel Lines
kinked.
A. Make sure that the TPIR return line is
Clear or replace the blocked line.
not blocked or kinked..
Return
Result: The TPIR return line and the fuel lines
B. If the TPIR return line is clear, confirm lines
between the EFLP and the TPIR are clear.
that the Electric Fuel Lift Pump (EFLP) is
operating. Make sure that fuel lines
Replace the EFLP.
between the EFLP and the TPIR are not
blocked or kinked.
If the fault is still present, contact the Technical


9. Low Fuel Rail Pressure Low fuel Result: The high-pressure fuel system has a leak.
rail
A. Make sure that the level of fuel in the pressure Rectify any fuel leaks.
fuel tank is sufficient. If necessary, fill
the fuel tank. Result: The Electric Fuel Lift Pump (EFLP) is not
operating correctly.
B. Inspect the high-pressure fuel system
for leaks. Refer to Troubleshooting, "Fuel Pump Relay Circuit
- Test".
C. Use the electronic service tool to
perform the "High Pressure Fuel Pump Result: There is air in the low-pressure fuel
Calibration". system.
D. Check that the Electric Fuel Lift Pump Identify the cause of the air in the system. Remove
(EFLP) is operating. the air from the low-pressure fuel system. Refer to
Systems Operation, Testing, and Adjusting, "Air in
E. Check for air in the low-pressure fuel Fuel - Test".
system. Refer to Systems Operation,
Testing, and Adjusting, "Air in Fuel - Result: The Fuel Rail Pressure Relief Valve Test
Test". fails.
F. Use the electronic service tool in order If excessive leakage is identified, replace the fuel
to perform the "Fuel Rail Pressure Relief rail. Refer to Disassembly and Assembly, "Fuel
Valve Test". Manifold (Rail) - Remove and Install".
Note: This test will identify excessive If the fault is still present, turn the isolator switch
leakage through the PLV in the fuel rail. to the OFF position and disconnect the electrical
connector from the EFLP.
With the isolator switch in the ON position,

measure the voltage at the harness connector for
the EFLP. The voltage must be between 10 VDC and
14 VDC for a 12 VDC system. The voltage must be
between 20 VDC and 28 VDC for a 24 VDC system. If
the voltage is below 10 VDC for a 12 VDC system,
investigate the cause. If the voltage is below 20
VDC for a 24 VDC system, investigate the cause.
Refer to Troubleshooting, "Fuel Pump Relay Circuit
- Test"
Turn the isolator switch to the OFF position and

then reconnect the electrical connector to the
EFLP.
If a repair has been performed to rectify a low

supply voltage to the EFLP, check for the original
fault. If the fault is still present, proceed to Test
Step 10.
Result: The fuel system is OK.

Table 5



Table 6
11. Return Pressure Relief Valve Test
A. Disconnect the return line from the secondary fuel filter

base and install a blank on the line. Install a temporary line and
a calibrated container to the filter base.
B. With the isolator switch in the ON position, measure fuel Result: The fuel flow is more
flow from the temporary line. than 5% below the acceptable
limit.
C. If the fuel flow is more than
300 mL/min (10.2 oz/min), replace the secondary fuel filter Replace the EFLP.
base. Refer to Disassembly and Assembly, "Fuel Filter Base -
Remove and Install (Twin Secondary Fuel Filter)". Result: The fuel flow is more
than 5% above the acceptable
D. Remove the temporary line and reconnect the return line. PRV test limit.

E. If the secondary fuel filter base has been replaced, attempt Contact the Technical
to start the engine. If the engine does not start, use the Communicator at a Cat dealer.
following procedure to check the fuel flow from the EFLP:
Result: The fuel flow is within
F. Disconnect the fuel inlet from the primary fuel filter. Place the acceptable limit.
the open end of the disconnected line into a calibrated
container. Proceed to Test Step 12.

G. With the isolator switch in the ON position, measure the
flow from the fuel line. Refer to the Illustration 9 for the
minimum acceptable fuel flow on a 12 VDC system. Refer to
the Illustration 10 for the minimum acceptable fuel flow on a
24 VDC system.

12. Check the Return Fuel Lines Return Result: The TPIR return line or
lines the fuel lines between the EFLP
A. Make sure that the TPIR return line is not blocked or kinked.. and the TPIR are blocked or
kinked.
Clear or replace the blocked

line.
Result: The TPIR return line

B. If the TPIR return line is clear, confirm that the Electric Fuel and the fuel lines between the
Lift Pump (EFLP) is operating. Make sure that fuel lines EFLP and the TPIR are clear.
between the EFLP and the TPIR are not blocked or kinked.
Replace the EFLP.
If the fault is still present,

contact the Technical

Troubleshooting C4.4 Marine Generator Set-Fuel Filter Is Restricted -

Secondary Fuel Filter
009- Fuel Filter Is Restricted - Secondary Fuel Filter
Note: The following codes are only applicable for engines with a pre-filter pressure sensor.
The Electronic Control Module (ECM) detects an abnormal differential pressure across the active secondary
fuel filter.
Use this procedure if one of the following codes is active.
Table 1
Diagnostic Trouble Codes for a Restricted Secondary Fuel Filter
J1939 Code Code Description Comments
The differential pressure across the active

Engine Fuel Filter Differential Pressure : secondary fuel filter is high.
95-15
High - least severe (1) No 3510 codes are active.
The code is logged.
Probable Cause
 Secondary Fuel filter blocked
 Sensor
Recommended Actions
Table 2
1. Diagnostic Codes
Result: A 95-15 code is present.
A. Connect the electronic service tool to the
diagnostic connector. Refer to Troubleshooting, Diagnostic
"Electronic Service Tools", if necessary. codes
Result: A 95-15 code is not present.

B. Determine if a diagnostic is active or recently
Return the unit to service.
logged.

Result: The code is no longer active.

2. Change the Active Fuel Filters
Use the electronic service tool to clear
A. Replace the active secondary fuel filter. Refer all logged diagnostic codes and verify
to the Operation and Maintenance Manual, "Fuel that the fault has been eliminated.
System Secondary Filter - Replace".
Fuel filter
change
B. Replace the active primary fuel filter. Refer to
the Operation and Maintenance Manual, "Fuel Result: The 95-15 code becomes active
System Primary Filter (Water Separator) Element - after changing the fuel filters.
Replace".

Result: A sensor does not read

atmospheric pressure while the engine
3. Fuel Pressure Sensors is not running.
A. Use the electronic service tool to compare the Troubleshoot the sensor circuit. Refer
status of the following parameters with the Fuel pressure to Troubleshooting, "Sensor Signal
engine not running: sensors (Analog Active) - Test".

· Secondary Fuel Filter Pre-filter Pressure Result: The sensors read atmospheric
· Secondary Fuel Filter Post-filter Pressure pressure while the engine is off.

a Cat dealer.
Troubleshooting C4.4 Marine Generator Set-Fuel Filter Is Restricted -

Primary Fuel Filter
010- Fuel Filter Is Restricted - Primary Fuel Filter
Note: The following codes are only applicable for engines with a pre-filter pressure sensor.
The Electronic Control Module (ECM) detects an abnormal differential pressure across the active primary
fuel filter.
Use this procedure if one of the following codes is active.
Table 1
Diagnostic Trouble Codes for a Restricted Primary Fuel Filter
J1939
Code
The differential pressure across the active

primary fuel filter is high.
Engine Fuel Filter (suction side) Differential
1382-15
Pressure : High - least severe (1) No 3510 codes are active.
The code is logged.
Probable Cause
 Primary fuel filter blocked
 Sensor
Recommended Actions
Table 2
1. Diagnostic Codes
Result: A 1382-15 code is present.
A. Connect the electronic service tool to the
diagnostic connector. Refer to Troubleshooting, Diagnostic
"Electronic Service Tools", if necessary. codes
Result: A 1382-15 code is not present.

B. Determine if a diagnostic is active or recently
logged.

Result: The code is no longer active.

2. Change the Active Fuel Filters
Use the electronic service tool to clear
A. Replace the active primary fuel filter. Refer to
all logged diagnostic codes and verify
the Operation and Maintenance Manual, "Fuel
that the fault has been eliminated.
System Primary Filter (Water Separator) Element -
Fuel filter
Replace".
change Return the unit to service.
B. Replace the active secondary fuel filter. Refer
Result: The 1382-15 code becomes
to the Operation and Maintenance Manual, "Fuel
active after changing the fuel filters.
System Secondary Filter - Replace".

Result: A sensor does not read
atmospheric pressure while the engine
is not running.
3. Fuel Pressure Sensors
Troubleshoot the sensor circuit. Refer
A. Use the electronic service tool to compare the
to Troubleshooting, "Sensor Signal
status of the following parameters with the Fuel pressure
(Analog Active) - Test".
engine not running: sensors

Result: The sensors read atmospheric
· Primary Fuel Filter Pre-filter Pressure
pressure while the engine is off.
· Primary Fuel Filter Post-filter Pressure

a Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Fuel Consumption Is Excessive

011- Fuel Consumption Is Excessive
Probable Causes
 Misreading of fuel level
 Fuel leakage
 Fuel quality
 Quality of oil
 Coolant temperature
 Prolonged operation at idle speed
 Reduced pressure of intake air
Recommended Actions
Table 1
1. Diagnostic Codes Diagnostic Result: A diagnostic code is present.

codes
Note: Certain diagnostic codes and/or event Troubleshoot the code and then verify
codes may cause high fuel consumption. that the fuel consumption is normal.
A. Use the electronic service tool to check for Result: A diagnostic code is not present.
active or logged codes.
Result: Fuel consumption is normal for

2. Misreading of Fuel Level
the operating conditions.
Note: Misreading of the fuel gauge can give a
false indication of fuel consumption. Fuel level

Result: Fuel consumption is high for the
A. Monitor the fuel consumption over a period
operating conditions.
of 50 engine hours.

Result: Evidence of a fuel leak is found.
Repair or replace the component that is

3. Fuel Leakage leaking fuel.
Fuel leaks
A. Check the engine for signs of fuel leakage. Result: No evidence of a fuel leak is
found.

Result: The fuel quality does not meet

4. Fuel Quality specifications.
Note: The grade of the fuel affects the rate of Drain the fuel system and replace the
fuel consumption. Refer to the engines fuel filters. Refer to the Operation and
Operation and Maintenance Manual for Maintenance Manual, "Fuel System
additional information. Primary Filter (Water Separator)
Element - Replace" and Operation and
Cold weather adversely affects the Maintenance Manual, "Fuel System Filter
characteristics of the fuel. Refer to the - Replace".
Operation and Maintenance Manual for
information on improving the characteristics of Fuel quality Fill the fuel system with fuel that meets
the fuel during cold-weather operation. the standard in the Operation and
Maintenance Manual, "Fluid
Recommendations".
A. Check the fuel quality. Refer to Systems
Operation, Testing, and Adjusting, "Fuel Quality Prime the fuel system. Refer to the
- Test". Operation and Maintenance Manual,
"Fuel System - Prime".
B. Refer to Operation and Maintenance Manual
for information on the proper characteristics of Result: The fuel quality meets
the fuel for the engine. specifications.

5. Quality of Oil Engine oil Result: The engine oil does not meet
quality the required specification.
Note: The nominal viscosity of the lubricating
oil that is used in the engine will affect the rate Refill the oil system with oil of an
of fuel consumption. The viscosity of lubricating
oil is defined by the SAE grade of the lubricating acceptable quality. Refer to the
oil. The grade of the lubricating oil must be applicable sections in the Operation and
correct for the ambient conditions. Lubricating Maintenance Manual.
oil for high ambient temperatures will affect
fuel consumption in cold ambient temperatures. Result: The engine oil meets the
required specification.
A. Check that the engine oil meets the required
specification. Refer to "Engine Oil" in the Proceed to Test Step 6.
Operation and Maintenance Manual, "Refill
Capacities".
6. Coolant Temperature
Result: The water temperature
Note: The operating temperature of the engine regulator is not operating correctly.
will affect the rate of fuel consumption.
Operation of the engine below the correct Replace the water temperature
temperature will increase fuel consumption. regulator. Verify that the repair
Coolant
Failure of the water temperature regulator can corrected the fault.
temperature
prevent the engine from operating at the

correct temperature. Result: The water temperature
regulator is operating correctly.
A. Check that the water temperature regulator
is operating correctly. Refer to Systems Proceed to Test Step 7.
Operation, Testing, and Adjusting, "Water
Temperature Regulator - Test".
Result: The engine is operating at idle

7. Prolonged Operation at Idle Speed speed for extended periods.
Note: Prolonged operation of the engine at idle When possible, stop the engine to
Extended idle
speed increases fuel consumption. conserve fuel.
operation

A. Check for extended periods of engine Result: The engine is not operating at
operation at idle speed. idle speed for extended periods.

Result: The air filter is restricted.

8. Air Intake and Exhaust System
Replace the air filter.
A. Check the air filter restriction indicator, if
Result: There are system restrictions.
equipped.
Air and
Exhaust Refer to Systems Operation/Testing and
B. Check the air intake and exhaust systems for
System Adjusting, "Air Inlet and Exhaust
the following defects:
restrictions System" for additional information on
the air inlet and exhaust systems.
· Blockages
· Restrictions
Result: The air intake and exhaust
· Damage to lines or hoses
system is OK.

9. Reduced Pressure of Intake Air
Result: There is a leak in the intake air
system.
Note: If the air pressure is lower than normal,
the same power can only be achieved by the
Repair the leak or replace the
following:
component that is causing the leak.
· Higher engine speed
Result: The turbocharger wastegate is
· Injection of more fuel
not operating correctly.
Intake air
Either of these conditions will increase the fuel
Replace the turbocharger.
consumption.
Result: The air intake system and the
A. Check all pipes from the outlets of the
wastegate are OK.
turbocharger compressor to the inlet manifold
for leaks.
a Cat dealer.
B. Check for the correct operation of the

wastegate in the turbocharger.
Troubleshooting C4.4 Marine Generator Set-Exhaust Temperature Is High

012- Exhaust Temperature Is High
The Electronic Control Module (ECM) monitors the temperature sensor in the outlet from the
turbocharger.
Certain operating conditions may cause the exhaust temperature to increase to a level that may damage
engine components. If a high exhaust temperature occurs, the ECM derates the engine in order to reduce
the exhaust temperature. The engine is derated only to a level that allows the exhaust temperature to
return to an acceptable level.
Table 1
Diagnostic Codes for High Exhaust Temperature
J1939
Code
The ECM has been powered for at least 2

seconds.
The engine has been running for at least 10

seconds.
Engine Exhaust Gas Temperature : High -
173-15
least severe (1)
There are no diagnostic trouble codes for the
exhaust gas temperature sensor.
There are no diagnostic trouble codes for the 5

VDC supply.
173-16 Engine Exhaust Gas Temperature : High - The ECM has been powered for at least 2
moderate severity (2) seconds.
seconds.
There are no diagnostic trouble codes for the

exhaust gas sensor.

VDC supply.
The engine will be derated.

seconds.
seconds.
Engine Exhaust Gas Temperature : High - There are no diagnostic trouble codes for the
173-0
most severe (3) exhaust gas sensor.
VDC supply.
Probable Causes
 Inlet system leak

 Engine operating conditions
 High altitude
 Obstructed heat exchanger or Air-to-Air Aftercooler (ATAAC)
Complete the procedure in the order in which the steps are listed.
Table 2
Result: Leakage was
found.
1. Check for Inlet System Leakage Repair the leaks. Return

Inlet system the unit to service.
A. Apply a light load to the engine and check for leakage leaks
from the inlet system downstream of the turbocharger. Result: Leakage was not
found.
2. Check the Engine Operating Conditions Type of Result: The code was

operation logged during a heavy
A. Use the electronic service tool to check the histograms. load.
Use the histograms to determine if the high exhaust
temperature occurred during normal operation. Reduce the load on the
If possible, interview the operator. Determine if the engine engine. Return the unit to
is being operated under heavy load. Ensure that the engine is service.
being operated at an acceptable engine speed.
Result: The code was not
If derates are suspected, reset the histogram and return the logged during a heavy
unit to service. If the histogram repopulates without fault load.
codes, the derating of the engine was under normal engine
operation. Proceed to Test Step 3.
Result: The flow of
coolant through the
exhaust manifold cooler is
obstructed.
3. Check for an Obstructed Exhaust Manifold Cooler
Clear any obstructions.
A. The exhaust gas temperature can increase if the coolant Obstructed
flow through the exhaust manifold cooler is obstructed. exhaust
Result: The exhaust
Check the coolant passages in the exhaust manifold cooler manifold cooler
manifold cooler is not
for obstructions or debris. Ensure that the flow of coolant
obstructed.
through the exhaust manifold cooler is adequate.

dealer.

Result: The ATAAC was

obstructed.
4. Check for an Obstructed ATAAC Clear any obstructions.

A. The intake manifold air temperature can increase if the Obstructed
flow through the ATAAC is obstructed. Check the ATAAC for ATAAC Result: The ATAAC was not
obstructions or debris. Ensure that the flow of air through obstructed.
the ATAAC is adequate.
dealer.

Troubleshooting C4.4 Marine Generator Set-Exhaust Has Excessive White

Smoke
013- Exhaust Has Excessive White Smoke
Note: Some white smoke may be present during cold start-up conditions and during acceleration after a
prolonged period at low idle. If the white smoke persists, there may be a fault.
Probable Causes
 ECM Flash file
 Starting aids
 Coolant temperature
 Cooling system
 Fuel quality
 Valve lash
 Electronic unit injectors
 Individual malfunctioning cylinder
Recommended Actions
Diagnostic Codes
Table 1
1. Diagnostic Codes
Result: A code is active or logged.
A. Establish communication between the
electronic service tool and the Electronic Troubleshoot any active codes before
Control Module (ECM). Refer to Diagnostic continuing with this procedure.
Troubleshooting, "Electronic Service codes
Tools", if necessary. Result: A code is not active or logged.
B. Determine if a code is active or Proceed to Test Step 2.

logged.

Result: The latest flash file is not installed.
Install the latest flash file. Refer to

2. ECM Flash File Troubleshooting, "ECM Software - Install" for
the correct procedure. Verify that the repair
Flash file
A. Verify that the latest flash file is eliminates the fault.

installed in the ECM.
Result: The latest flash file is installed.

3. Starting Aids Result: The starting aids are not operating

correctly.
A. Check operation of starting aids.
Verify that the starting aids are operating Make the necessary repairs. Verify that the
correctly. Refer to Troubleshooting, repair corrected the fault.
Starting aid
"Glow Plug Starting Aid - Test".

Result: The starting aids are operating
B.Check the configuration screen on the correctly.
electronic service tool in order to verify
that ether injection is not enabled. Proceed to Test Step 4.

4. Coolant Temperature Coolant Result: The water temperature regulator is not

temperature operating correctly.
A. Check that the water temperature
regulator is operating correctly. Refer to Replace the water temperature regulator.
Systems Operation, Testing, and Verify that the repair corrected the fault.
Adjusting, "Water Temperature Regulator
Result: The water temperature regulator is
- Test".


Result: There is an internal coolant leak.

5. Cooling System
Make the necessary repairs. Verify that the
A. Check for an internal coolant leak into Internal repair eliminated the fault.
the cylinder and/or the exhaust. Refer to coolant leak
Systems Operation/Testing and Result: There is not an internal coolant leak.
Adjusting, "Cooling System".

Result: The fuel quality is not OK.
Drain the fuel system and replace the fuel

filters. Refer to the Operation and Maintenance
Manual, "Fuel System Primary Filter (Water
Separator) Element - Replace" and Operation
and Maintenance Manual, "Fuel System Filter -
6. Fuel Quality
Replace".
A. Check the fuel quality. Refer to
Fill the fuel system with fuel that meets the
Systems Operation, Testing, and
standard in the Operation and Maintenance
Adjusting, "Fuel Quality - Test". Fuel
Manual, "Fluid Recommendations".

B. Refer to Operation and Maintenance
Prime the fuel system. Refer to the Operation
Manual for information on the proper
and Maintenance Manual, "Fuel System -
characteristics of the fuel for the engine.
Prime".

Verify that the procedure has eliminated the
noise.
Result: The fuel quality is OK.
Result: The valve lash is not correct.
Investigate the cause of the excessive valve

7. Valve Lash
lash. Refer to Systems Operation, Testing, and
Adjusting, "Engine Valve Lash - Inspect/Adjust"
Note: The valve lash can affect the Valve lash
for the correct procedure.
performance of the engine.
A. Check the valve lash.
Result: The valve lash is correct.

8. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are
compression outside the specifications.
Investigate the cause and rectify any faults.
Note: Possible causes of low compression are

shown in the following list:
· Loose glow plugs
· Faulty piston
A. Perform a compression test. Refer to · Faulty piston rings
Systems Operation, Testing, and · Worn cylinder bores

Adjusting, "Compression - Test ". · Worn valves
Result: The results of the compression test are

OK.

Result: A faulty injector is indicated.
Remove any faulty electronic unit injectors.

Refer to Disassembly and Assembly, "Electronic
Unit Injector - Remove".
9. Electronic Unit Injectors
Install new electronic unit injectors. Refer to
Disassembly and Assembly, "Electronic Unit
A. Use the electronic service tool to
Injector - Install".
perform the automatic "Cylinder Cut Out
Test". Electronic
Repeat the automatic "Cylinder Cut Out Test".
Unit Injectors
If the fault is still apparent, remove the
Note: If the compression test that was
replacement electronic unit injector and install
performed in Test Step 8 was
the original electronic unit injector. Refer to
satisfactory, the "Cylinder Cut Out Test"
will identify any faulty injectors.
Injector - Remove" and Disassembly and

Assembly, "Electronic Unit Injector - Install".
Result: All injectors are OK.

10. Individual Malfunctioning Cylinders Cylinders Result: The test indicates a faulty cylinder.

A. With the engine speed at a fast idle, Investigate the cause of the fault on any
use the electronic service tool to perform cylinder that is not operating. Investigate the
the manual "Cylinder Cut Out Test". cause of the fault on any cylinder that is
operating below normal performance.
As each cylinder is cut out, listen for a
change in the sound from the engine. Result: The test indicates that all cylinders are
When a cylinder is cut out, there should OK.
be a noticeable change in the sound of
the engine. Contact the Technical Communicator at a Cat
dealer.
If a change in the sound of the engine is
not noted, the isolated cylinder is not
operating under normal conditions. If the
isolation of a cylinder results in a change
in the sound that is less noticeable, the
cylinder may be operating below normal
performance.

Troubleshooting C4.4 Marine Generator Set-Exhaust Has Excessive Black

Smoke
014- Exhaust Has Excessive Black Smoke
Probable Causes
 Parameters in the Electronic Control Module (ECM)
 Air intake system or exhaust system
 Valve lash
 Turbocharger
Recommended Actions
Table 1
1. Diagnostic Codes
Result: A diagnostic code is present.
Note: Certain diagnostic codes and/or
event codes may cause poor Engine Derate
Troubleshoot the code.
performance. Refer to in the electronic or Diagnostic
service tool. Codes
Result: A diagnostic code is not present.


check for active or logged codes.

2. Parameters in the Electronic Parameters Result: The parameters are not correct.

Control Module (ECM)
Input the correct parameters. Refer to
A. Use the electronic service tool to Troubleshooting, "Configuration Parameters"
for additional information.
verify that the correct parameters are
being used. Refer to Troubleshooting,
Result: The parameters are correct.
"System Configuration Parameters" for
additional information.

Result: There are restrictions in the air inlet or

3. Air Intake and Exhaust System exhaust system.
A. Observe the check engine lamp. Make the necessary repairs, Refer to Systems
Check for an air filter restriction Operation/Testing and Adjusting, "Air Inlet and
indicator, if equipped. Replace a Exhaust System - Inspect" for additional
Restrictions
plugged air filters. Refer to the information.

Operation and Maintenance Manual.
Result: There are no restrictions in the air
B. Check the air inlet and exhaust inlet or exhaust system.
system for restrictions and/or leaks.

Result: The valve lash is not correct.
Investigate the cause of the excessive valve

4. Valve Lash
lash. Refer to Systems Operation, Testing, and
Adjusting, "Engine Valve Lash - Inspect" for the
A. Check the valve lash. Refer to Valve lash
correct procedure.
Systems Operation, Testing and
Adjusting, "Engine Valve Lash - Inspect".
Result: The valve lash is correct.


5. Turbocharger Turbocharger Result: There is a fault on the turbocharger.

Note: The turbocharger that is installed Repair the turbocharger or replace the
on the engine is a non-serviceable item. turbocharger. Refer to Disassembly and
If any mechanical fault exists, then the Assembly, "Turbocharger - Remove" and
faulty turbocharger must be replaced. Disassembly and Assembly, "Turbocharger -
Install".
A. Ensure that the mounting bolts for
the turbocharger are tight. Result: The turbocharger is OK.
B. Check that the oil drain for the Proceed to Test Step 6.
turbocharger is not blocked or
restricted.
C. Check that the compressor housing

for the turbocharger is free of dirt and
debris. Make sure that the housing is not
damaged.
D. Check that the turbine housing for

the turbocharger is free of dirt and
debris. Make sure that the housing is not
damaged.
E. Check that the turbine blades rotate

freely in the turbocharger.


outside the specifications.

6. Low Compression (Cylinder
Pressure) · Loose glow plugs
Cylinder · Faulty piston
A. Perform a compression test. Refer to compression · Faulty piston rings
Systems Operation, Testing, and · Worn cylinder bores
Adjusting, "Compression - Test ". · Worn valves

OK.

Result: A faulty injector is indicated.
Remove any faulty electronic unit injectors.

Unit Injector - Remove".
7. Electronic Unit Injectors
Install new electronic unit injectors. Refer to
perform the automatic "Cylinder Cut Out
Test". Electronic Unit
Injectors
Note: If the compression test that was
replacement electronic unit injector and
performed in Test Step 6 was
install the original electronic unit injector.
satisfactory, the "Cylinder Cut Out Test"
will identify any faulty injectors.
Unit Injector - Remove" and Disassembly and


8. Individual Malfunctioning Cylinders Cylinders Result: The test indicates a faulty cylinder.

A. With the engine speed at a fast idle,
use the electronic service tool to
perform the manual "Cylinder Cut Out
Test".
Investigate the cause of the fault on any
As each cylinder is cut out, listen for a cylinder that is not operating. Investigate the
change in the sound from the engine. cause of the fault on any cylinder that is
When a cylinder is cut out, there should operating below normal performance.
be a noticeable change in the sound of
the engine. Result: The test indicates that all cylinders are
OK.
not noted, the isolated cylinder is not Contact the Technical Communicator at a Cat
operating under normal conditions. If dealer.
the isolation of a cylinder results in a
change in the sound that is less
noticeable, the cylinder may be

Troubleshooting C4.4 Marine Generator Set-Engine Vibration Is Excessive

015- Engine Vibration Is Excessive
Refer to Systems Operation, Testing, and Adjusting for additional information on determining the cause of
this condition.
Probable Causes
 Engine supports
 Driven equipment
Recommended Actions
Table 1
1. Engine Supports
Result: The mounts and brackets are loose
A. Inspect the mounts and the brackets and/or broken.
while you run the engine through the
speed range. Look for mounts and brackets Replace the mounts and brackets that are
that are loose and/or broken. Engine loose and/or broken.
supports
B. Check the alignment of the following Result: The mounts and brackets are not loose
before operating the engine under load for and/or broken.
any length of time:
· Mounts
· Coupling
Result The driven equipment and the
alignment are not OK.
2. Driven Equipment
Repair or replace the driven equipment.
A. Inspect the mounting bolts for the
Driven
driven equipment. Inspect the alignment
equipment Result: The driven equipment and the
and the balance of the driven equipment.
alignment are OK.
B. Inspect the coupling.

Result: The results of the compression test

are outside the specifications.

· Loose glow plugs
A. Perform a compression test. Refer to
compression · Faulty piston rings
· Worn cylinder bores
"Compression - Test ".
· Worn valves


are OK.

4. Electronic Unit Injectors Electronic Result: A faulty injector is indicated.

Unit Injectors
A. Use the electronic service tool to Remove any faulty electronic unit injectors.
perform the automatic "Cylinder Cut Out Refer to Disassembly and Assembly,
Test". "Electronic Unit Injector - Remove".
Note: If the compression test that was Install new electronic unit injectors. Refer to
performed in Test Step 4 was satisfactory, Disassembly and Assembly, "Electronic Unit
the "Cylinder Cut Out Test" will identify Injector - Install".
any faulty injectors.
Refer to Disassembly and Assembly,
"Electronic Unit Injector - Remove" and

5. Individual Malfunctioning Cylinders

use the electronic service tool to perform
Result: The test indicates a faulty cylinder.
the manual "Cylinder Cut Out Test".
cylinder that is not operating. Investigate the
change in the sound from the engine.
cause of the fault on any cylinder that is
When a cylinder is cut out, there should be
a noticeable change in the sound of the Cylinders
engine.
Result: The test indicates that all cylinders
are OK.
Contact the Technical Communicator at a Cat
dealer.

performance.

Troubleshooting C4.4 Marine Generator Set-Engine Top Speed Is Not

Obtained
016- Engine Top Speed Is Not Obtained
Note: If this fault occurs only under load, refer to Troubleshooting, "Acceleration Is Poor or Throttle
Response Is Poor".
Probable Causes
 ECM parameters
 Fuel supply
 Individual malfunctioning cylinders
Recommended Actions
Table 1
1. Diagnostic Codes
Diagnostic Result: There are active or logged
A. Establish communication between the electronic codes codes.
service tool and the Electronic Control Module (ECM).
Refer to Troubleshooting, "Electronic Service Tools", if Troubleshoot any codes before
necessary.
continuing with this procedure.
B. Download the "Warranty Report" from the engine
ECM before performing any troubleshooting or Result: There are no active or
clearing diagnostic trouble codes. logged codes.
Troubleshoot any active codes before continuing with Proceed to Test Step 2.
this procedure.

Result: The parameters are not

configured correctly.
2. ECM Parameters
Correctly configure the parameters.
A. Use the electronic service tool to verify that the
Verify that the configuration change
correct engine parameters are being used. Refer to Parameters
eliminated the fault.
Troubleshooting, "System Configuration Parameters"
and Troubleshooting, "Customer Configuration
Result: The parameters are
Parameters" for additional information.
configured correctly.


Result: The air filter is plugged.
Clean or replace the air filter. Refer

to the Operation and Maintenance
Manual for further information.
Result: There are restrictions in the
equipped. Clean plugged air filters or replace plugged
air inlet or exhaust system.
air filters. Refer to the Operation and Maintenance Restrictions
Manual.
Make the necessary repairs, Verify
that the repair eliminated the fault.
B. Check the air inlet and exhaust system for
restrictions and/or leaks.
Result: There are no restrictions in

the air inlet or exhaust system.

4. Fuel Supply Fuel system Result: The fuel contains solidified

wax.
A. Ensure that the vent in the fuel cap is not filled
with debris. Replace the fuel with fuel of the
correct specification for the
B. Ensure that the fuel supply valve (if equipped) is in ambient conditions.
the full OPEN position.
Result: There are fuel supply lines
C. If the temperature is below that are restricted.
0 °C (32 °F), check for solidified fuel (wax).
Replace any damaged or restricted
D. Check the primary filter/water separator for water fuel lines.
Replace the primary fuel filter and
the secondary fuel filters. Refer to
the Operation and Maintenance
Result: There is air in the fuel

system.
Prime the fuel system. Refer to

in the fuel.
Adjusting, "Fuel System - Prime".
E. Check for fuel supply lines that are restricted.
Result: The diesel fuel is
contaminated.
F. Replace the primary and secondary fuel filters.
Drain the fuel tank and the fuel
G. Check the diesel fuel for contamination. Refer to
system.
Systems Operation, Testing, and Adjusting, "Fuel
Quality - Test".
H. Check for air in the fuel system. Refer to Systems
Operation, Testing, and Adjusting, "Air in Fuel - Test".

Fill and prime the fuel system with
fuel of the correct specification.
Refer to Systems Operation,
Testing, and Adjusting, "Fuel System
- Prime".
Result: The fuel supply is OK.

Table 2



Table 3
6. Return Pressure Relief Valve Test

PRV test Result: The fuel flow is more than 5% below
A. Disconnect the return line from the the acceptable limit.
secondary fuel filter base and install a
blank on the line. Install a temporary line Replace the EFLP.
and a calibrated container to the filter
base. Result: The fuel flow is more than 5% above
the acceptable limit.
B. With the isolator switch in the ON
position, measure fuel flow from the Contact the Technical Communicator at a Cat
temporary line. dealer.
C. If the fuel flow is more than Result: The fuel flow is within the acceptable
300 mL/min (10.2 oz/min), replace the limit.
secondary fuel filter base. Refer to
Disassembly and Assembly, "Fuel Filter Proceed to Test Step 7.
Base - Remove and Install (Twin Secondary
Fuel Filter)".


flow from the EFLP:

container.

minimum acceptable fuel flow on a 12 VDC
system. Refer to the Illustration 5 for the
minimum acceptable fuel flow on a 24 VDC
system.


kinked.
Return lines Result: The TPIR return line and the fuel lines
B. If the TPIR return line is clear, confirm
Replace the EFLP.
blocked or kinked.
If the fault is still present, proceed to Test

Step 8.


are outside the specifications.

· Loose glow plugs
"Compression - Test ".
· Worn valves


are OK.


Unit Injectors
perform the automatic "Cylinder Cut Out Refer to Disassembly and Assembly,
Test". "Electronic Unit Injector - Remove".
Refer to Disassembly and Assembly,
"Electronic Unit Injector - Remove" and


When a cylinder is cut out, there should be
a noticeable change in the sound of the Cylinders
engine.
Result: The test indicates that all cylinders
are OK.
dealer.

performance.

Troubleshooting C4.4 Marine Generator Set-Engine Shutdown Occurs

Intermittently
017- Engine Shutdown Occurs Intermittently
Note: Use this procedure only if the engine shuts down completely and the engine must be restarted.
Probable Causes
 Fuel supply
 Switches
Recommended Actions
Table 1
1. Diagnostic Codes Codes Result: There are active codes.

Troubleshoot any active codes
Note: Certain diagnostic codes and/or event codes may before continuing with this
cause an engine shutdown. procedure.

A. Connect the electronic service tool and check for Result: There are no active codes.
active codes and for logged codes.

Result: There are suspect

connectors.
Use the electronic service tool to

perform the "Wiggle Test".
Repair connectors that are suspect
A. Check for the correct installation of the ECM J1/P1 Connectors
or replace connectors that are
and the J2/P2 connectors. Check for correct installation
suspect.
of the fuel injector connectors.

Result: There are no suspect
connectors.

3. Fuel Supply
A. Ensure that the vent in the fuel cap is not filled with
debris.
B. Ensure that the fuel supply valve (if equipped) is in

the full OPEN position.
Result: The fuel supply is not OK.
C. If the temperature is below
Service the fuel system or repair
0 °C (32 °F), check for solidified fuel (wax).
the fuel system components, as
Fuel system necessary.
D. Check the primary filter/water separator for water in

the fuel.
Result: The fuel supply is OK.
E. Check for fuel supply lines that are restricted.

F. Check the diesel fuel for contamination. Refer to
Systems Operation, Testing, and Adjusting, "Fuel Quality
- Test".
G. Check for air in the fuel system. Refer to Systems

Operation, Testing, and Adjusting, "Air in Fuel - Test".

4. Switches Switches Result: The shutdown switches

and wiring are not OK.
A. Check the isolator switch input to the ECM.
that the repair eliminated the
fault.
B. Check any engine shutdown switches and associated Result: The shutdown switches
wiring. and wiring are OK.


Troubleshooting C4.4 Marine Generator Set-Engine Overspeeds

018- Engine Overspeed
This procedure covers the following diagnostic trouble code:
Table 1
Diagnostic Trouble Code for Engine Overspeed
J1939
Code
The engine has exceeded the value that is programmed into the
Electronic Control Module (ECM) for 0.6 seconds.
Engine Overspeed
190-15 There are no diagnostic trouble codes for the speed/timing
Warning - Level 1
sensors.
The engine has been running for at least 3 seconds.
The engine has exceeded the value that is programmed into the
Electronic Control Module (ECM) for 0.6 seconds.
There are no diagnostic trouble codes for the speed/timing

Engine Overspeed sensors.
190-0
Warning - Level 3
The engine has been running for at least 3 seconds.

The ECM limits the flow of fuel in order to prevent the engine speed from exceeding the value that is
programmed into the ECM. When the engine speed has dropped to less than the value that is programmed
into the ECM, the 190-XX code will be reset.
If the engine speed exceeds the value that is programmed into the ECM, the ECM illuminates the warning
lamp and a 190-XX code is logged. Factory passwords are required in order to clear the code.
The history of engine overspeeds can be viewed on the electronic service tool.
Probable Causes
 Turbocharger
 Combustible gases or liquid in the intake air
Recommended Actions
Table 2
Result: The turbocharger is
1. Turbocharger
leaking oil into the intake air.
Note: The turbocharger that is installed on the engine is a
Replace the turbocharger.
nonserviceable item. If any mechanical fault exists, then
Turbocharger
the faulty turbocharger must be replaced.
Result: The turbocharger is not
leaking oil into the intake air.
A. Check for any oil that may be leaking into the intake
air.

Result: The atmosphere has

combustible gases.
Do not operate the engine in

an environment with
2. Combustible Gases or Liquid in the Intake Air combustible gases.
A. Check for combustible gases in the surrounding Result: There is combustible

atmosphere. liquid in the air intake.
Air quality
B. Check for combustible liquid in the air intake. Remove the liquid. Investigate
and rectify the cause of liquid
C. Check for correct operation of the ether starting aid (if ingestion
equipped).
Result: The intake air does not
contains combustible gases.


Troubleshooting C4.4 Marine Generator Set-Engine Misfires, Runs Rough or

Is Unstable
019- Engine Misfires, Runs Rough or Is Unstable
Note: If the fault is intermittent and the fault cannot be duplicated, refer to Troubleshooting, "Power Is
Intermittently Low or Power Cutout Is Intermittent".
Note: If the fault only occurs under certain conditions, test the engine under those conditions. Examples
of certain conditions are high rpm, full load, and engine operating temperature. Troubleshooting the
symptoms under other conditions can give misleading results.
Probable Causes
 Fuel supply
 High-pressure fuel pump SCV
 High-pressure fuel pump
Recommended Actions
Table 1
1. Diagnostic Codes
Result: There are active codes.
service tool and the Electronic Control Module (ECM). Troubleshoot any active codes before
Refer to Troubleshooting, "Electronic Service Tools", if continuing with this procedure.
Codes
necessary.

Result: There are no active codes.
B. Download the "Warranty Report" from the engine ECM
before performing any troubleshooting or clearing Proceed to Test Step 2.
diagnostic trouble codes.

2. Fuel Supply Fuel Result: There is air in the fuel

supply system.
A. Visually check the fuel tank for fuel. The fuel gauge
may be faulty. Prime the fuel system. Refer to
B. Ensure that the fuel supply valve (if equipped) is in the Adjusting, "Fuel System - Prime".
full OPEN position.
C. Check the primary filter/water separator for water in
the fuel. Replace the fuel. Replace the
primary and secondary fuel filters.
D. Check for fuel supply lines that are restricted. Verify that the repair eliminated the
fault.
E. Check for air in the fuel system. Refer to Systems
Operation, Testing, and Adjusting, "Air in Fuel - Test". Result: The fuel quality is OK.
F. Obtain a fuel analysis in order to confirm that the Proceed to Test Step 3.
correct fuel is being used. Refer to Systems
Operation/Testing and Adjusting, "Fuel Quality - Test" for

Table 2
3. Transfer Pump Inlet Regulator (TPIR) Flow Test
Refer to Illustration 1.
A. Disconnect the TPIR return line from the drain port on the
return line.
B. Connect a temporary drain line to the drain port on the TPIR.

Result: The fuel flow is
greater than the minimum
C. Place the end of the temporary drain line into a suitable
limit.
D. With the isolator switch in the ON position but the engine not TPIR flow
running, use a suitable multimeter to measure the input voltage rate
limit.



Table 3
4. Return Pressure Relief Valve Test PRV test Result: The fuel flow is more than 5% below
the acceptable limit.
secondary fuel filter base and install a Replace the EFLP.
blank on the line. Install a temporary line
and a calibrated container to the filter Result: The fuel flow is more than 5% above
base. the acceptable limit.
B. With the isolator switch in the ON Contact the Technical Communicator at a Cat
position, measure fuel flow from the dealer.
temporary line.

300 mL/min (10.2 oz/min), replace the
secondary fuel filter base. Refer to
Disassembly and Assembly, "Fuel Filter
Base - Remove and Install (Twin
Secondary Fuel Filter)".


Result: The fuel flow is within the acceptable
limit.
flow from the EFLP:

container.

minimum acceptable fuel flow on a 12
VDC system. Refer to the Illustration 5 for
the minimum acceptable fuel flow on a 24
VDC system.


kinked.
Return lines Result: The TPIR return line and the fuel lines
B. If the TPIR return line is clear, confirm
Replace the EFLP.
blocked or kinked.
If the fault is still present, proceed to Test

Step 6.

6. High-Pressure Fuel Pump SCV HP fuel pump Result: The solenoid valve test fails.
SCV
A. Use the electronic service tool to Replace the HP fuel pump SCV and solenoid
perform a solenoid test on the fuel assembly.
injection pump. Refer to Troubleshooting,
"Solenoid Valve - Test". Result: The solenoid valve test passes
successfully.

Result: There are diagnostic codes associated

7. High-Pressure Fuel Pump
with the high-pressure fuel pump.
Note: The fuel injection pump that is
Diagnose the codes. Refer to Troubleshooting,
installed by the factory is a
"Troubleshooting with a Diagnostic Code".
nonserviceable item. If any fault occurs
within the fuel injection pump, the fuel
HP fuel pump If necessary, replace the high-pressure fuel
injection pump must be replaced.
pump.
Result: The high-pressure fuel pump is OK.
select the correct screen in order to
display any diagnostic trouble codes that
relate to the fuel injection pump.


outside the specifications.

· Loose glow plugs
Adjusting, "Compression - Test ".
· Worn valves


OK.


Unit Injectors
perform the automatic "Cylinder Cut Out Refer to Disassembly and Assembly, "Electronic
Test". Unit Injector - Remove".
replacement electronic unit injector and install
the original electronic unit injector. Refer to
Injector - Remove" and Disassembly and


When a cylinder is cut out, there should
be a noticeable change in the sound of Cylinders
the engine.
Result: The test indicates that all cylinders are
OK.
dealer.

performance.

Troubleshooting C4.4 Marine Generator Set-Engine Has Mechanical Noise

(Knock)
020- Engine Has Mechanical Noise (Knock)
Probable Causes
 Electrical connections
 Fuel injection
 Fuel quality
 Correct lubrication
 Isolate the source of the noise.
 Valve train components
 Gear train and lower end components
 Crankshaft
Recommended Actions
Table 1
1. Diagnostic Codes
Result: There are active codes.
Troubleshoot any active codes
service tool and the Electronic Control Module
before continuing with this
(ECM). Refer to Troubleshooting, "Electronic Diagnostic
procedure.
Service Tools", if necessary. codes

Result: There are no active codes.
B. Download the "Warranty Report" from the
engine ECM before performing any troubleshooting
or clearing diagnostic trouble codes.

Result: There are suspect

connectors.
Repair connectors that are suspect

or replace connectors that are
2. Electrical Connections suspect.
A. Check for the correct installation of the ECM P1 Connectors Perform the "Wiggle Test" on the
and P2 connectors. Check for correct installation electronic service tool
of the fuel injector connectors.
Result: There are no suspect
connectors.

3. Fuel Injection Fuel System Result: The test was not successful.

Verification
A. Perform the "Fuel System Verification Test" in Test Diagnose the fault and then repair
the "Diagnostic Tests" under the "Diagnostics" the fault.
menu.
Reset all active codes and clear all
logged codes.
Verify that the repair has eliminated

the noise.
Result: The test was successful.


Note: Refer to Operation and

Maintenance Manual for information
4. Fuel Quality
on the proper characteristics of the
fuel for the engine. If necessary,
A. Obtain a fuel analysis in order to confirm that
Fuel
the correct fuel is being used for the engine. Refer
Replace the fuel. Verify that the
to Systems Operation/Testing and Adjusting, "Fuel
repair eliminated the noise.
System Quality Test" for the proper procedure.


5. Correct Lubrication
A. Check for correct lubrication of the valve

Result: The oil passages are blocked
components. Check for sufficient lubrication
or the engine does not have correct
between the injector tappets and the rocker arms.
lubrication.
B. Check for blocked oil passages. Oil passages
must be clean. Clean any oil passages that are
that the repair eliminated the noise.
questionable. Refer to the Disassembly and
Lubrication
Assembly for additional information.
Result: The oil passages are not
blocked and the engine has proper
C. Inspect the engine oil filters for ferrous
lubrication.
material.
D. Obtain an S-O-S oil analysis. The analysis will

contribute to a better understanding of oil
contamination and the origin of the contamination.

Result An engine accessory is the

source of the noise.
Repair the engine accessory and/or

6. Isolate the Source of the Noise replace the engine accessory, as
Engine
necessary.
accessory
A. Attempt to isolate the source of the noise.

Result An engine accessory is not the
source of the noise.

7. Valve Train Components Valve train Result: The valve train components

are damaged.
A. Check the valve lash. Refer to Systems
Operation, Testing, and Adjusting, "Valve Lash -
Inspect/Adjust".
B. Check for damage to valve train components.

Remove the valve cover. Check the following items
for damage:
· Camshaft
· Valve springs
that the repair eliminated the noise.
· Camshaft followers
Result: The valve train components
· Rocker shaft
are not damaged.
· Bridges

· Pushrods
Refer to the Disassembly and Assembly for

C. Check for valves that do not move freely. If

necessary, remove the cylinder head and inspect
the valves.
Refer to the Disassembly and Assembly for
Result: The gear train or lower end

components are damaged.
8. Gear Train and Components of the Lower End
Replace any damaged parts.
Gear train
A. Inspect the gear train and lower end

components. Result: The gear train or lower end
components are not damaged.

Result: The crankshaft or the

related components are damaged or
worn.
9. Crankshaft
Repair or replace any damaged
A. Inspect the crankshaft and the related
parts. Verify that the repair
components. Look for worn thrust plates and wear
eliminated the noise.
on the crankshaft. Crankshaft

Result: The crankshaft or the
B. Inspect the connecting rod bearings and the
related components are not
bearing surfaces on the crankshaft. Make sure that
damaged or worn.
the bearings are in the correct position.

Contact the Technical Communicator
at a Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Engine Has Early Wear
021- Engine Has Early Wear
Probable Causes
 Incorrect maintenance intervals and/or incorrect oil

 Contaminated engine oil
 Low oil pressure
 Leaks in air intake system
 Dirt in fuel
Recommended Actions
Table 1
Result: The engine oil was not

changed at the interval that is
recommended by the Operation and
Maintenance Manual.
1. Incorrect Maintenance Intervals and/or Use the recommended grade of oil.

Incorrect Oil
Change the engine oil at the interval
Maintenance
A. Use engine oil that is recommended and that is recommended. Repair or
intervals
change the engine oil at the interval that is replace any damaged parts.

recommended by the engines Operation and
Maintenance Manual. Result: The engine oil was changed at
the interval that is recommended by
Manual.

2. Contaminated Engine Oil Contamination Result: The oil is contaminated.

A. Obtain an S-O-S oil analysis. The analysis will Determine the reason for any
identify oil contamination. contamination of the engine oil and
make the necessary repairs. Drain the
B. Check the oil filter bypass valve. crankcase and refill the crankcase
with clean engine oil. Install new
Note: If the oil filter bypass valve is open, the oil engine oil filters. Refer to the engines
will not be filtered. Operation and Maintenance Manual.

Result: The oil filter bypass valve is
open.
Replace the oil filter element. Refer

to the Operation and Maintenance
Manual.
Check the oil filter bypass valve for a

weak spring or for a broken spring. If
the spring is broken, replace the
spring. Verify that the oil bypass
valve is operating correctly.
Result: The oil is not contaminated.

3. Low Oil Pressure
Note: Engine oil that is contaminated with Result: Analysis indicates that the oil
another liquid can cause low engine oil pressure. is contaminated.
High engine oil level can be an indication of
contamination. Replace the oil and the oil filter.
Refer to the Operation and
A. Obtain an analysis of the engine oil. Maintenance Manual.
B. Check the inlet screen on the suction tube and Result: The inlet tube has a
remove any material that may be restricting restriction.
engine oil flow.
Clear the obstruction. Verify the
Note: The inlet screen of the suction tube for the Oil pressure repair.
engine oil pump can have a restriction. This
restriction will cause cavitation and a loss of Result: The oil pressure is low.
engine oil pressure.
Refer to Troubleshooting, "Oil
When some components of the engine show wear Pressure Is Low" for the testing
in a short time, the cause can be a restriction in a procedure. Repair any identified
passage for engine oil. An indicator for the engine faults..
oil pressure may indicate sufficient pressure, but
a component is worn due to a lack of lubrication. Result: The oil pressure is normal.
In such a case, look at the passage for the engine
oil supply to the component. Refer to Systems Proceed to Test Step 4.
Operation/Testing and Adjusting, "Lubrication
System" for additional information.

4. Leaks in Air Intake System

Result: There are air leaks.
Note: A leak in the air intake system may allow
unfiltered air into the engine.
Repair any leaks.
Air leak
A. Inspect the air intake system for streaks which
Result: There are no air leaks.
may indicate a leakage of unfiltered air. Inspect
all of the gaskets and the connections. Refer to
Systems Operation, Testing, and Adjusting, "Air

Inlet and Exhaust System" for more information.

5. Dirt in Fuel Fuel and fuel Result: The fuel has contamination.

filters
A. Remove the fuel filters. Inspect the fuel filters Determine the cause of any
contamination and make the
necessary repairs.
for contamination.
Install new fuel filters. Refer to the
Note: Contaminants in the fuel such as hydrogen
Operation and Maintenance Manual.
sulfide and sulfur can lead to the formation of

acids in the crankcase.
Result: The fuel is not contaminated.
B. Obtain a fuel analysis.

at a Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Engine Does Not Crank

022- Engine Does Not Crank
Probable Causes
 Battery cables and batteries

 Switches and/or circuit breakers
 Starting motor relay, solenoid, and starting circuit
 Starting motor and/or flywheel ring gear
 Engine accessories and generator
 Hydraulic lock
Recommended Repairs
Table 1
1. Battery Cables and Batteries Batteries and Result: The batteries and

A. Inspect the main power switch, battery posts, and
battery cables for loose connections and for corrosion. If
cables are not OK.
the battery cables are corroded, remove the battery
cables and clean the battery cables. Tighten any loose
Make the necessary
connections.
repairs.
cables
B. Inspect the batteries.
Result: The batteries and
cables are OK.
C. Charge the batteries. Refer to Special Instruction,
SEHS7633, "Battery Test Procedure".

Test the batteries. Refer to Special Instruction, SEHS9249,
"Use of 4C-4911 Battery Load Tester for 6 v, 8 v, and 12 v
Lead Acid Batteries".
Result: The switches
and/or circuit breakers
are not OK.
2. Switches and/or Circuit Breakers
Make the necessary
Switches and/or repairs.
A. Check any switches and/or circuit breakers that may
circuit breakers
interfere with the engine cranking. Refer to the electrical
Result: The switches
schematic for additional information.
and/or circuit breakers

are OK.

Result: The starting
motor relay, solenoid, or
starting circuit are not
OK.
3. Starting Motor Relay, Solenoid, and Starting Circuit
Starting motor Make the necessary
A. Test the operation of the starting motor circuit. Refer relay, solenoid, repairs.
to Systems Operation/Testing and Adjusting, "Electric and circuit
Starting System - Test". Result: The starting
motor solenoid and circuit
are OK.

4. Starting Motor and/or Flywheel Ring Gear Starter pinion and Result: The starter pinion
flywheel ring gear and flywheel ring gear are
A. Test the operation of the starting motor. are OK not OK.

B. Check the wiring for the starting motor. Refer to Make the necessary
Systems Operation, Testing, and Adjusting, "Electric repairs.
Starting System - Test".
Result: The starting
C. Check the pinion clearance. Inspect the pinion and the motor and flywheel ring
flywheel ring gear for damage. Refer to Systems gear are OK.
Operation/Testing and Adjusting, "Electrical System" for
additional information. Proceed to Test Step 5.

5. Engine Accessories and Generator

Result: The engine
A. Ensure free movement of the driveline. accessories or generator
are not OK.
B. Remove and inspect any engine accessories that may
lock up the engine. Make the necessary
Engine accessories repairs.
The following list contains examples of engine accessories and transmission
that may lock up the engine: Result: The engine
accessories and generator
· Hydraulic pump that is driven from the rear gear group are OK.
· Air compressor
· Engine oil pump Proceed to Test Step 6.
· Other components that are driven by the engine

6. Hydraulic Lock
Note: If an injector has been replaced, evacuate any fluids

from the cylinder and attempt to start the engine. Fuel
will flow from the cylinder head into the cylinders when a
unit injector is removed. Result: The engine has a
hydraulic lock.
A. Check for fluid in the cylinders by removing the
individual unit injectors. Check for damaged seals. Make the necessary
repairs.
B. If there was excessive fuel in the cylinder, replace the
Hydraulic lock
seals and reinstall the injector. Drain any excess fuel from Result: The engine

the cylinder head. rotates freely.
C. If a mechanical problem is suspected, disassemble the Contact the Technical

engine. Refer to the Disassembly and Assembly manual. Communicator at a Cat
Inspect the internal components for the following dealer.
conditions:
· Seizure
· Broken components
· Bent components

Troubleshooting C4.4 Marine Generator Set-Engine Cranks but Does Not

Start
023- Engine Cranks but Does Not Start
If possible, download the "Warranty Report" from the engine ECM before performing this procedure.
Probable Causes
 Visible faults
 Speed/timing sensor
 Low-pressure fuel system
 High-pressure fuel system
 Glow plugs
Recommended Actions
NOTICE
Do not crank the engine continuously for more than 30 seconds. Allow the
starting motor to cool for two minutes before cranking the engine again.
Table 1
Result: A diagnostic code is present.

1. Diagnostic Codes
Troubleshoot the code and then reset
the histogram.
Diagnostic codes
A. Use the electronic service tool to check for
Result: A diagnostic code is not
active or logged codes.
present.


2. Visible Faults Visible faults Result: The fuel supply valve (if

equipped) is not in the OPEN position.
A. Check that the fuel supply valve (if
equipped) is in the OPEN position. Move the fuel supply valve to the
OPEN position.
B. Check for the correct level of fuel, oil, and
coolant. Result: The level of fuel, oil, or
coolant is not correct.
C. Check for water in the primary fuel
filter/water separator. Replenish any fluids with an incorrect
level.
D. If the ambient temperature is below
0 °C (32 °F), check the specification of engine Result: Water is present in the
oil and oil for the machine. primary fuel filter/water separator.
E. Visually inspect the engine for the following Drain any water from the primary fuel
faults: filter/water separator.
· Missing components Result: Battery voltage is low.

· Damaged components
Check the battery. Refer to
Troubleshooting, "Battery Problem".
· Damaged electrical cables or loose electrical
Result: The correct specification of
cables
engine oil and oil for the machine is
· Oil leaks
not in use.
· Fuel leaks
· All fuel filters are correctly installed.
Replenish the system with oil of the
correct specification for the ambient
F. Check that the battery voltage is correct.
conditions.
If the ambient temperature is below
Result: The cranking speed is less
0 °C (32 °F), check that the correct
than 150 rpm.
specification of engine oil and oil for the
machine is used.
Investigate the cause of the low
cranking speed and rectify, as
G. Use the electronic service tool to check the
necessary.
average cranking speed of the engine.
Result: All checks are OK.


Result: The air filter is restricted.
Replace the air filter.

Result: There are system restrictions.
equipped.
Air and Exhaust Refer to Systems Operation/Testing
System and Adjusting, "Air Inlet and Exhaust
B. Check the air intake and exhaust systems for
restrictions System" for additional information on
the following defects:
the air inlet and exhaust systems.
· Blockages
Result: The air intake and exhaust
· Restrictions
system is OK.
· Damage to lines or hoses

4. Speed/Timing Sensors
Result: The speed/timing sensors are
not operating correctly.
A. Crank the engine and observe the engine
speed on the electronic service tool status
Test the speed/timing sensors. Refer
screen. Refer to Troubleshooting,
to Troubleshooting, "Speed/Timing -
"Speed/Timing - Test" for additional Speed/timing
Test".
information. sensor

Result: The speed/timing sensors are
Upon initial cranking, the status for engine
speed may indicate that the engine speed signal
is abnormal. This message will be replaced with
an engine speed once the ECM is able to

calculate a speed from the signal.

Result: The fuel tank level is low.
Fill the fuel tank.
Result: The fuel contains solidified

wax.
Replace the fuel with fuel of the

correct specification for the ambient
conditions.
Result: There are fuel supply lines

that are restricted or not correctly
installed.
Install the fuel lines correctly.

5. Low-Pressure Fuel System Replace any damaged or restricted
fuel lines.
A. Visually check the fuel tank for fuel.
Note: The fuel gauge may be faulty. Replace the primary fuel filter and
B. If the temperature is below the Operation and Maintenance
0 °C (32 °F), check for solidified fuel (wax). Manual for further information.
Low-pressure
C. Check for fuel supply lines that are Result: There is air in the fuel system.
fuel system
restricted or not correctly installed.

Prime the fuel system. Refer to
E. Check for air in the fuel system and that the Systems Operation, Testing, and
fuel system is primed. Adjusting, "Fuel System - Prime".
D. Check the diesel fuel for contamination. Result: The diesel fuel is

Refer to Systems Operation, Testing, and contaminated.
Adjusting, "Fuel Quality - Test".
Drain the fuel tank and the fuel
system.

Fill and prime the fuel system with

fuel of the correct specification.
Refer to Systems Operation, Testing,
and Adjusting, "Fuel System - Prime".
Result: The low-pressure fuel system

is OK.
Table 2

6. Transfer Pump Inlet Regulator (TPIR) Flow Test
Refer to Illustration 1.
A. Disconnect the TPIR return line from the drain port on the
return line.
B. Connect a temporary drain line to the drain port on the TPIR.

greater than the minimum
C. Place the end of the temporary drain line into a suitable
limit.
D. With the isolator switch in the ON position but the engine not TPIR flow
running, use a suitable multimeter to measure the input voltage rate
limit.



Table 3
7. Return Pressure Relief Valve Test PRV test Result: The fuel flow is more than 5%
below the acceptable limit.
secondary fuel filter base and install a blank on Replace the EFLP.
the line. Install a temporary line and a
calibrated container to the filter base. Result: The fuel flow is more than 5%
above the acceptable limit.
B. With the isolator switch in the ON position,
measure fuel flow from the temporary line. Contact the Technical Communicator at a
Cat dealer.
300 mL/min (10.2 oz/min), replace the Result: The fuel flow is within the
secondary fuel filter base. Refer to acceptable limit.
Disassembly and Assembly, "Fuel Filter Base -
Remove and Install (Twin Secondary Fuel Proceed to Test Step 8.
Filter)".
D. Remove the temporary line and reconnect

the return line.
E. If the secondary fuel filter base has been

replaced, attempt to start the engine. If the
engine does not start, use the following
procedure to check the fuel flow from the
EFLP:
F. Disconnect the fuel inlet from the primary

fuel filter. Place the open end of the
disconnected line into a calibrated container.
G. With the isolator switch in the ON position,

measure the flow from the fuel line. Refer to
the Illustration 4 for the minimum acceptable
fuel flow on a 12 VDC system. Refer to the
Illustration 5 for the minimum acceptable fuel
flow on a 24 VDC system.

Result: The TPIR return line or the fuel

lines between the EFLP and the TPIR are
blocked or kinked.
A. Make sure that the TPIR return line is not
blocked or kinked..
Result: The TPIR return line and the fuel
Return lines
lines between the EFLP and the TPIR are
B. If the TPIR return line is clear, confirm that
clear.
the Electric Fuel Lift Pump (EFLP) is operating.
Make sure that fuel lines between the EFLP and
Replace the EFLP.
the TPIR are not blocked or kinked.

If the fault is still present, proceed to
Test Step 9.

9. High-Pressure Fuel System High-pressure Result: The absolute fuel rail pressure is

fuel system less than
A. Use the electronic service tool to check the 25 MPa (3625 psi).
absolute fuel rail pressure while the engine is
cranking at a minimum speed of 150 rpm. Check for fuel leaks in the high-pressure
fuel system. Rectify any fuel leaks and
then recheck the pressure in the fuel rail.
Use the electronic service tool to perform

a solenoid test on the fuel injection
pump. Refer to Troubleshooting,
"Solenoid Valve - Test".
Check the Pressure Limiting Valve (PLV)

in the fuel rail for leakage. If the valve is
leaking, replace the valve and recheck
the pressure in the fuel rail.
Check for fuel in the engine oil system. If

fuel is suspected in the oil system, take
an engine oil sample for analysis. Refer to
the Operation and Maintenance Manual,
"Engine Oil Sample - Obtain".
If the analysis confirms that there is fuel

in the engine oil system, investigate the
cause.
Result: The absolute fuel rail pressure is

greater than
25 MPa (3625 psi).
Use the electronic service tool to make

sure that the status of the electronic unit
injectors is not "Disabled".
If the injectors are disabled but the

injectors have not been intentionally
disabled, proceed to Test Step 10.
Use the electronic service tool to perform

an injector solenoid test. Refer to
Troubleshooting, "Injector Solenoid
Circuit - Test". If the engine will not
start, proceed to Test Step 12.

Result: Installation of the latest flash file

does not eliminate the fault.

Cat dealer.
Note: This consultation can greatly

reduce the repair time.
If the Technical Communicator

recommends the use of a test ECM, install
10. Electronic Control Module (ECM) a test ECM. Refer to Troubleshooting,
"Replacing the ECM".
ECM
Make sure that the latest flash file for the

application is installed in the ECM. Attempt to start the engine. If the engine
will not start, install the original ECM and
then proceed to Test Step 11.
If the engine starts normally, reconnect

the suspect ECM and then verify that the
fault returns when the suspect ECM is
installed.
If the engine will not start with the

suspect ECM, replace the ECM and then
check that the engine starts normally.

11. High-Pressure Fuel Pump HP fuel pump Result: The timing of the high-pressure
fuel pump is incorrect.
Correct the timing of the high-pressure
fuel pump. Refer to Disassembly and
Assembly, "Fuel Injection Pump -
Remove" and Disassembly and Assembly,
"Fuel Injection Pump - Install".
With the high-pressure fuel pump

correctly timed, check that the engine
starts normally.
If the engine will not start, proceed to

A. Check the timing of the high-pressure fuel Test Step 12.
pump. Refer to Systems Operation, Testing,
and Adjusting, "Fuel Injection Timing - Check". Result: The timing of the high-pressure
fuel pump is correct.
Replace the high-pressure fuel pump.

Refer to Disassembly and Assembly, "Fuel
Injection Pump - Remove" and
Disassembly and Assembly, "Fuel Injection
Pump - Install".
Check that the engine starts normally.
If the engine will not start, proceed to

Test Step 12.

12. Glow Plugs Result: One or more of the glow plugs are

faulty.
Note: Faulty glow plugs will only affect engine
starting when the ambient temperature is Replace any faulty glow plugs. Refer to
between Disassembly and Assembly, "Glow Plug -
5° C (41° F) and Glow plugs Remove and Install".
−25° C (−13° F).
Check that the engine starts normally.
A. Check the operation of the glow plugs. Refer
to Troubleshooting, "Glow Plug Starting Aid - If the engine will not start, proceed to
Test". Test Step 13.

13. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression
compression test are outside the specifications.
Systems Operation, Testing, and Adjusting, Investigate the cause and rectify any
"Compression - Test ". faults.

Note: Possible causes of low compression
are shown in the following list:
· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn valves

test are OK.

Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Electronic Service Tool Does

Not Communicate
024- Electronic Service Tool Does Not Communicate
Probable Causes
 Configuration of the communications adapter

 Communication adapter and/or cables
 Electrical power supply to the diagnostic connector
 Electronic service tool and related hardware
 Electrical power supply to the Electronic Control Module (ECM)
 Data Link
Recommended Actions
Table 1
Result: The correct "Communications

1. Configuration of the Communications Communications Interface Device" is not selected.
Adapter adapter configuration
Select the correct "Communications
A. Access "Preferences" under the Interface Device".
"Utilities" menu on the electronic service
tool. Result: The correct port is not
selected for use by the
B. Check for hardware that uses the same communication adapter.
ports as the communications adaptor. Select the correct port for use by the
communication adapter.
Note: The most commonly used port is

"COM 1".
Result: Other hardware is sharing the

same port with the communications
adaptor.
Exit or close the software programs

for that device.
Result: The communications adaptor

is correctly configured.
Result: The connectors are not

correctly installed.
Repair or replace the connectors, as
A. Check for correct installation of the P1
Electrical connectors necessary.
and P2 ECM connectors and of the

connector for the electronic service tool.
Result: The connectors are OK.


Result: The firmware or driver files

are not the most current files.
Update the firmware or driver files to

the most current files.
3. Communication Adapter and/or Cables
Result: The cable between the
A. Check that the firmware and driver files communication adapter and the
are the most current files for the type of diagnostic connector is not correct.
communication adapter that is being used.
Replace the cable between the
Verify that the correct cable is being used communication adapter and the
between the communication adapter and Comms adaptor and diagnostic connector with the correct
the diagnostic connector. cables type.

B. Disconnect and then reconnect the Result: The laptop computer has a
cable that attaches the communication Windows operating system.
adapter to the diagnostic connector.
Restart the laptop computer in order
C. Check the operating system on the to eliminate the possibility of a
laptop computer. conflict in the software.

Result: The adaptor and cables are
OK.

4. Electrical Power Supply to the Electrical power Result: Battery voltage is not present
Diagnostic Connector between terminals A and B of the
diagnostic connector.
A. Use a multimeter to check that battery
voltage is present between terminals A and Investigate the cause and repair, as
B of the diagnostic connector. necessary.
Result: Battery voltage is present
Note: If the communication adapter is not between terminals A and B of the
receiving power, the LED display on the diagnostic connector.
communication adapter will be off.

Result: The same fault occurs on a

5. Electronic Service Tool and Related
different engine.
Hardware
Check the electronic service tool and
A. Connect the electronic service tool to a
the related hardware for faults.
different engine. Hardware

Result: The fault does not occur on a
Note: This process eliminates the
different engine.
electronic service tool and the related
hardware as the fault.

Result: The power supply to the ECM

6. Electrical Power Supply to the
is incorrect.
Electronic Control Module (ECM)
Investigate the cause and repair, as
A. Check the power supply to the ECM.
necessary.
Refer to Systems Operation, Testing, and Power to ECM
Adjusting, "Charging System - Test".
Result: The power supply to the ECM
is OK.
Note: If the ECM is not receiving battery
voltage, the ECM will not communicate.

Result: A fault was identified in the

data link and the link is now OK.
7. Data Link
A. Troubleshoot the Data Link for possible Data link
faults. Refer to Troubleshooting, "Data Result: The data link is OK.
Link - Test".
at a Cat dealer.

Troubleshooting C4.4 Marine Generator Set-ECM Will Not Accept Factory

Passwords
025- ECM Will Not Accept Factory Passwords
Probable Causes
One of the following items may not be recorded correctly on the electronic service tool:
 Passwords
 Serial numbers
 Total tattletale
 Reason code
Recommended Actions
1. Verify that the correct passwords were entered. Check every character in each password. Remove
the electrical power from the engine for 30 seconds and then retry.
2. Verify that the electronic service tool is displaying the "Enter Factory Passwords" dialog box.
3. Use the electronic service tool to verify that the following information has been entered correctly:
o Engine serial number
o Serial number for the electronic control module
o Serial number for the electronic service tool
o Total tattletale
o Reason code
For additional information, refer to Troubleshooting, "Factory Passwords".
Troubleshooting C4.4 Marine Generator Set-ECM Does Not Communicate

with Other Modules
026- ECM Does Not Communicate with Other Modules
Probable Causes
 Data Link
 Electronic Control Module (ECM)
 CAN data link
Recommended Actions
1. Connect the electronic service tool to the diagnostic connector. If the ECM does not communicate
with the electronic service tool, refer to Troubleshooting, "Electronic Service Tool Does Not
Communicate".
2. Ensure that the following items are correctly installed and undamaged. Refer to Troubleshooting,
"Electrical Connectors - Inspect".
o P1 and P2 connectors on the ECM
o Wiring to display modules
o Wiring to other control modules
3. Troubleshoot the data link for possible faults. Refer to Troubleshooting, "Data Link - Test".
4. Verify that the CAN data link does not have an open or short circuit. Refer to Troubleshooting,
"CAN Data Link - Test".
Troubleshooting C4.4 Marine Generator Set-Cylinder Is Noisy

027- Cylinder Is Noisy
Probable Causes
 Fuel quality
 Valve train components
 Low Compression (Cylinder Pressure)
 Injectors
 Pistons
Recommended Actions
Table 1
1. Diagnostic Codes
A. Establish communication Result: A diagnostic trouble code is active or logged.

between the electronic service
tool and the Electronic Control Troubleshoot the active or logged codes.
Module (ECM).
Codes
Result: A diagnostic trouble code is not active or

B. Download the "Warranty logged.
Report" from the engine ECM
before performing any Proceed to Test Step 2.
troubleshooting or clearing
diagnostic trouble codes.

Drain the fuel system and replace the fuel filters. Refer
to the Operation and Maintenance Manual, "Fuel System
2. Fuel Quality
Primary Filter (Water Separator) Element - Replace" and
Operation and Maintenance Manual, "Fuel System Filter
A. Check the fuel quality. Refer
- Replace".
to Systems Operation, Testing,
and Adjusting, "Fuel Quality -
Fill the fuel system with fuel that meets the standard in
Test".
Fuel the Operation and Maintenance Manual, "Fluid
Recommendations".
B. Refer to Operation and
Maintenance Manual for
Prime the fuel system. Refer to the Operation and
information on the proper
Maintenance Manual, "Fuel System - Prime".
characteristics of the fuel for
the engine.
Verify that the procedure has eliminated the noise.

3. Valve Train Components

Valve train Result: Valve train components are damaged.
A. Check the valve lash. Refer to
Troubleshooting, "Valve Lash Is Make the necessary repairs, Verify that the repair has
Excessive". eliminated the noise.
B. Check for damage to valve Result: The valve train components are not damaged.
train components. Remove the
valve cover from the suspect Proceed to Test Step 4.
cylinders. Check the following
items for damage:
· Valve springs
· Rocker shaft
· Bridges

· Pushrods
· Camshaft followers
Refer to the Disassembly and

Assembly for additional
information.

Result: The results of the compression test are outside

the specifications.
Note: Possible causes of low compression are shown in

4. Low Compression (Cylinder the following list:
Pressure)
· Loose glow plugs
Cylinder
A. Perform a compression test. · Faulty piston
compression
Refer to Systems Operation, · Faulty piston rings

Testing, and Adjusting, · Worn cylinder bores
"Compression - Test ". · Worn valves
Result: The results of the compression test are OK.

Unit Injectors
A. Use the electronic service tool Remove any faulty electronic unit injectors. Refer to
to perform the automatic Disassembly and Assembly, "Electronic Unit Injector -
"Cylinder Cut Out Test". Remove".
Note: If the compression test Install new electronic unit injectors. Refer to
that was performed in Test Step Disassembly and Assembly, "Electronic Unit Injector -
9 was satisfactory, the "Cylinder Install".
Cut Out Test" will identify any
faulty injectors. Repeat the automatic "Cylinder Cut Out Test". If the
fault is still apparent, remove the replacement
electronic unit injector and install the original
electronic unit injector. Refer to Disassembly and
Assembly, "Electronic Unit Injector - Remove" and
Disassembly and Assembly, "Electronic Unit Injector -
Install".


Result: One or more pistons are worn or damaged.
Replace any worn or damaged parts.

6. Pistons
Pistons Verify that the repair has eliminated the noise.
A. Inspect the pistons for

damage and wear.
Result: All pistons are OK.

Contact the Technical Communicator at a Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Crankcase Fumes Disposal Tube

Has Oil Draining
028- Crankcase Fumes Disposal Tube Has Oil Draining
A discharge of condensation from the breather is normal. The discharge is normally clear but can contain
soot. Although the discharge can contain oil vapor, any liquid oil must be limited to 0.5 g (0.02 oz) per
hour. An oil discharge in excess of 0.5 g (0.02 oz) must be investigated.
Probable Causes
 Breather filter
 Engine oil level
 One-way valve
 Excessive blow-by
Recommended Actions
Typical breather canister

(1) Filter element
(2) Breather canister
Table 1
1. Breather Filter Result: The filter element (1) is not correctly

installed or the element is damaged.
A. Check that filter element (1) is correctly
installed and that the element is not Install the filter element correctly or replace the
damaged. filter element.
B. Check for restrictions or blockages in Result: There are restrictions or blockages in the

breather canister (2) . Filter breather canister.

Note: If a new filter element blocks before Clean the interior of the breather canister.
the service period is completed, the
blockage can indicate a fault in the engine. Result: The breather is clean and operating
correctly.
Note: In cold ambient conditions, ice can
form in the outlets of the breather canister. Proceed to Test Step 2.

Result: The engine oil level is high.
Check for contamination of the oil with fuel or

coolant. Refer to Troubleshooting, "Oil Contains
Fuel" or Troubleshooting, "Oil Contains Coolant".
2. Engine Oil Level
Oil
level If the engine oil is not contaminated, remove the
A. Check the oil level in the engine.
excess oil.

Result: The engine oil level is correct.

Table 2
3. One-way Valve One-way Result: The one-way valve does not

valve operate correctly.
A. Disconnect breather drain hose (1) from one-way
valve (2) and then remove the one-way valve from the Install a replacement valve. Refer to
engine. Refer to Disassembly and Assembly, "Crankcase Disassembly and Assembly, "Crankcase
Breather - Remove". Breather - Install".
B. Use a suitable cleaning solution to flush the one-way

valve. Result: The one-way valve operates
C. Connect a low-pressure air supply breather drain
correctly.
hose side of the one-way valve. The air must flow freely
through the valve.
D. Connect a low-pressure air supply crankcase side of

the one-way valve. The valve must block the airflow.

Result: There is excessive blow-by.
Replace the breather filter.

4. Excessive Blow-by
Investigate the cause of the excessive
Note: Excessive blow-by increases the flow of fumes
blow-by. Refer to Troubleshooting,
through the breather system and can cause the breather Blow-by
"Oil Consumption Is Excessive".
filter to block. The pressure relief valve may then open.
Result: The blow-by is not excessive.
A. Check the engine for excessive blow-by.

at a Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Crankcase Breather Ejects Oil

029- Crankcase Breather Ejects Oil
The crankcase breather canister includes a pressure relief valve that prevents a build-up of excessive
pressure in the breather canister.
In normal operation of the engine, the pressure relief valve remains closed. If there is evidence of oil
staining on the cylinder head behind the breather canister, perform the following procedure in order to
diagnose the fault.
Probable Causes
 Breather filter
 Breather hoses
 Excessive blow-by
Recommended Actions
Typical breather canister
(1) Filter element(2) Breather canister
Table 1
Result: The filter element (1) is not

correctly installed or the element is
damaged.
1. Breather Filter
Install the filter element correctly or
replace the filter element.
A. Check that filter element (1) is correctly installed
and that the element is not damaged.
Result: There are restrictions or
Filter blockages in the breather canister.
B. Check for restrictions or blockages in breather

canister (2) .
Clean the interior of the breather
canister.
Note: In cold ambient conditions, ice can form in the
outlets of the breather canister.
Result: The breather is clean and


2. Breather Hoses Hoses Result: One or more of the hoses is

pinched or blocked.
A. Make sure that the oil return hose from the breather
canister is not pinched or blocked. Clear the hose or replace the hose.
B. Make sure that the breather outlet hose from the Result: All of the hoses are clear.
breather canister is not pinched or blocked.

Result: There is excessive blow-by.
3. Excessive Blow-by Replace the breather filter.
Note: Excessive blow-by increases the flow of fumes Investigate the cause of the excessive
through the breather system and can cause the blow-by. Refer to Troubleshooting, "Oil
Blow-by
breather filter to block. The pressure relief valve may Consumption Is Excessive".

then open.
Result: The blow-by is not excessive.
A. Check the engine for excessive blow-by.
a Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Coolant Temperature Is High

030- Coolant Temperature Is High
This procedure covers the following diagnostic trouble codes:
Table 1
Diagnostic Trouble Codes for High Coolant Temperature
The coolant temperature has been at

109° C (228° F) for 10 seconds.

seconds.
Engine Coolant Temperature : High - least
110-15
severe The engine has been running for at least 185
seconds.
There are no electrical faults or battery faults

on the circuit.

110-16 Engine Coolant Temperature : High - The coolant temperature has been at
moderate severity 111° C (232° F) for 10 seconds.

seconds.

seconds.
on the circuit.

The coolant temperature has been at

114° C (237° F) for 10 seconds.

seconds.
Engine Coolant Temperature : High - most
110-0
severe The engine has been running for at least 185
seconds.

on the circuit.

Access the monitoring system on the electronic service tool in order to view the current trip points for
these codes.
Probable Causes
 Coolant level
 Coolant temperature sensor
 Radiator and hoses
 Radiator cap and pressure relief valve
 Water temperature regulator
 Engine cooling fan (if equipped)
 Coolant quality
 Coolant pump
Recommended Actions
Table 2
Result: Diagnostic codes are not

1. Diagnostic Codes present.
A. Use the electronic service tool to check for Diagnostic Return the unit to service.
diagnostic codes that relate to the temperature in Codes
the cooling system. Result: Diagnostic codes are present.

2. Coolant Level Engine coolant

level Result: The engine coolant level is
A. Check the coolant level. low.
Check the cooling system for leaks.
Refer to Troubleshooting, "Coolant
Level is Low" for additional
information. Repair any leaks
immediately.
Result: The engine coolant level is

OK.
Result: The temperature sensor is not

accurate.
Troubleshoot the circuit and the

coolant temperature sensor. Refer to
Troubleshooting, "Sensor Signal
(Analog, Passive) - Test".
3. Coolant Temperature Sensor
Coolant Result: The temperature sensor is
A. Compare the reading for the coolant
temperature reading accurately.
temperature on the electronic service tool to the
sensor
reading for the coolant temperature on a
For engines with radiator cooling,
calibrated test gauge.

For engines with keel cooling,
For engines with raw water cooling,


Result: The radiator fins are blocked

or damaged.
4. Radiator and Hoses
Remove any dirt and/or debris and
Note: This Test Step is only applicable to engines straighten any bent fins.
with radiator cooling.
Result: The radiator has internal
A. Check the radiator fins for dirt, debris, and/or Radiator and blockage.
damage. hoses
Remove the blockage.
B. Check for collapsed hoses and/or other
restrictions. Result: The radiator fins are not
damaged and the radiator does not
C. Check the radiator for internal blockage. have an internal blockage.


5. Keel Cooling System and Hoses

Cooling system Result: The cooling system is blocked
Note: This Test Step is only applicable to engines and hoses or damaged.
with keel cooling.
A. Check the cooling system for dirt, debris,
and/or damage.
repair/replace any damaged
components.
restrictions.
Result: The skin tank has internal
C. Check that the auxiliary water pump is
blockage.
Remove the blockage.
D. Check the skin tank for internal blockage.
Result: The cooling system is not
E. Ensure that the skin tank size is sufficient. An
damaged and the skin tank does not
undersized skin tank does not have enough area
have an internal blockage.
for the effective release of heat. An undersized
skin tank may cause the engine to run at a
temperature that is higher than normal. The

normal temperature is dependent on the ambient
water temperature.

6. Raw Water Cooling System and Hoses

Result: The cooling system or the raw
water inlet is blocked or damaged.
Note: This Test Step is only applicable to engines
with raw water cooling.
repair/replace any damaged
A. Check the cooling system for dirt, debris,
components.
and/or damage.
Result: The heat exchanger has
Cooling system internal blockage.
restrictions.
and hoses
Remove the blockage or replace the
C. Check that the auxiliary water pump is
heat exchanger.
Result: The cooling system is not
D. Check the raw water inlet for blockage or
damaged and the heat exchanger
restriction.
does not have an internal blockage.
E. Check the heat exchanger for internal
blockage.

7. Filler Cap and Pressure Relief Valve Result: The pressure relief valve
and/or the water temperature
A. Pressure-test the cooling system. Refer to regulator are not operating properly.
"Cooling System" for the correct procedure. Clean the components or replace the
components.
Filler cap
B. Check that the seating surfaces of the pressure

relief valve and the filler cap are clean and Result: The pressure relief valve
undamaged. and/or the water temperature
regulator are operating properly.
C. Check operation of the pressure relief valve
and/or the water temperature regulator. Proceed to Test Step 8.

Result: The water temperature

regulator is not operating correctly.
8. Water Temperature Regulator Replace the water temperature

regulator. Refer to Disassembly and
Water
Check the water temperature regulator for Assembly, "Water Temperature
Temperature
correct operation. Refer to Systems Operation, Regulator - Remove and Install".
Regulator
Testing, and Adjusting, "Cooling System" for the

proper procedure. Result: The water temperature
regulator is operating correctly.

Result: The drive belt is not

tensioned correctly.
Check the automatic tensioner and

9. Engine Cooling Fan (If Equipped) replace the tensioner, if necessary.
A. Check for a loose drive belt. Result: The fan is damaged.

Fan and drive
Note: A loose fan drive belt will cause a reduction belt Repair the fan or replace the fan, as
in the air flow across the radiator. necessary. Refer to Disassembly and
Assembly, "Fan - Remove and Install".
B. Check the engine cooling fan for damage.
Result: The fan is OK and the fan belt
is tensioned correctly.

10. Coolant Quality Coolant Result: The coolant is not of an

acceptable quality.
A. Check the quality of the coolant. Refer to the
Operation and Maintenance Manual, "Refill Drain and refill the coolant system
Capacities and Recommendations - Coolant". with coolant of the correct quality.
Refer to the Operation and
Maintenance Manual, "Refill
Capacities and Recommendations -
Coolant".
Result: The coolant is of an
acceptable quality.

Result The coolant pump is damaged

or not operating correctly.
If necessary, replace the coolant

11. Coolant Pump
pump. Refer to Disassembly and
Assembly, "Water Pump - Remove"
A. Inspect the impeller of the coolant pump for
and Disassembly and Assembly,
damage and/or erosion. Coolant pump
"Water Pump - Install".

B. Make sure that the drive gear is not loose on
Result The coolant pump is not
the drive shaft of the coolant pump.
damaged and the pump is operating

correctly.

Result: Bubbles are present in the

coolant or the coolant is discolored.
Check the cylinder head gasket. Refer

to the recommended action for the
12. Cylinder Head Gasket cylinder head gasket within
Troubleshooting, "Oil Contains
Switch off the engine and allow the engine to cool Coolant".
to below normal working temperature. Remove
the pressure cap for the coolant system. Start the Check the cylinder head for flatness.
Cylinder Head
engine and inspect the coolant for the presence of Refer to the recommended action for
gasket
bubbles or discoloration of the coolant. checking flatness of the cylinder head

within Systems Operation, Testing,
Note: If bubbles are present in the coolant or the and Adjusting, "Cylinder Head -
coolant is discolored, combustion gases may be Inspect".
entering the cooling system.
Result: There is no evidence of gas
leakage into the cooling system.

at a Cat dealer.

Troubleshooting C4.4 Marine Generator Set-Coolant Pressure Is High

031- Coolant Pressure Is High
The following codes are associated with high coolant pressure:
Table 1
Diagnostic Trouble Codes for High Coolant Pressure
J1939
Code
The ECM detects that the pressure in the engine

Engine Coolant Pressure : High - coolant system is above the trip point.
109-15
least severe The warning lamp is lit and the code is logged.


coolant system is above the trip point.
Engine Coolant Pressure : High -
109-16 The warning lamp is lit and the code is logged.
moderate severity
Engine power will be derated.


coolant system is above the trip point.
Engine Coolant Pressure : High -
109-0 The warning lamp is lit and the code is logged.
most severe

Probable Causes
The only known cause for this symptom is a faulty relief valve in the coolant system filler cap. Refer to
Systems Operation, Testing, and Adjusting, "Cooling System - Test" for information on testing the filler cap
relief valve.
If the filler cap relief valve is operating correctly, contact the Technical Communicator at a Cat dealer.
Troubleshooting C4.4 Marine Generator Set-Coolant Level Is Low

032- Coolant Level Is Low
Use this procedure when the engine coolant level is repeatedly found to be low or any of the following
diagnostic codes are active:
Table 1
Diagnostic Trouble Codes for Low Coolant Level
The coolant level is low for 10 seconds with the

engine running.
Engine Coolant Level : Low - least The ECM has been powered for at least 2 seconds.
111-17
severe There are no electrical faults or battery faults on
the circuit.

111-18 Engine Coolant Level : Low - moderate The coolant level is low for 10 seconds with the
severity engine running.
There are no electrical faults or battery faults on
the circuit.

The coolant level is low for 60 seconds with the

engine not running.
Engine Coolant Level : Low - most
111-1 There are no electrical faults or battery faults on
severe (3)
the circuit.

Note: Diagnostic codes will only be present if a coolant level switch is installed.

Inspect the cooling system. Refer to Systems Operation, Testing, and Adjusting, "Cooling System - Test" for
Troubleshooting C4.4 Marine Generator Set-Coolant Contains Oil

033- Coolant Contains Oil
Probable Causes
 Engine oil cooler

 Cylinder head
 Cylinder block
Recommended Actions
Table 1
1. Engine Oil Cooler Oil Cooler Result: A leak is found in the engine oil cooler.

A. Drain the coolant from the cooling Install a new oil cooler. Refer to Disassembly and
system. Drain the lubricating oil from the Assembly, "Engine Oil Cooler - Remove" and
engine oil cooler. Refer to the Operation Disassembly and Assembly, "Engine Oil Cooler -
and Maintenance Manual for more Install" for the correct procedure.
information.
Flush the cooling system. Refer to the Operation
B. Check for leaks in the engine oil cooler. and Maintenance Manual for the correct
Refer to Systems Operation, Testing, and procedure. Refill the cooling system with the
Adjusting, "Cooling System" for the proper correct coolant. Refer to the Operation and
procedure. Maintenance Manual for the recommended
coolant and capacities.
Refill the engine with the proper oil after the

leak has been repaired. Refer to the Operation
and Maintenance Manual for the correct oil
capacities and viscosity.
Result: A leak was not found in the engine oil

cooler.

Result: The cylinder head gasket does not show

2. Cylinder Head Gasket signs of damage or leakage.
A. Remove the cylinder head. Refer to C. Install a new cylinder head gasket and install
Disassembly and Assembly, "Cylinder Head Cylinder the cylinder head. Refer to Disassembly and
- Remove". head Assembly, "Cylinder Head - Install" .
gasket
B. Inspect the cylinder head gasket for Result: The cylinder head gasket shows signs of
faults and any signs of leakage. damage or leakage.

Result: A fault is found in the cylinder head.

3. Cylinder Head
Repair the cylinder head or replace the cylinder
head. Install the cylinder head. Refer to
A. Check for cracks in the cylinder head.
Cylinder Disassembly and Assembly, "Cylinder Head -
Perform a leak test on the cylinder head.
head Install".
Refer to System Operation, Testing and

Adjusting, "Cylinder Head - Inspect" for the
Result: A fault is not found in the cylinder head.
correct procedure.


Result: A fault is found in the cylinder block.
Repair the cylinder block or replace the cylinder

4. Cylinder Block block. Inspect the top deck. Refer to the Reuse
and Salvage Guidelines for the proper inspection
A. Inspect the top face of the cylinder procedure.
Cylinder
block for faults and signs of leakage.
block
Refer to Systems Operation, Testing, and Result: No fault is found in the cylinder block.

Adjusting, "Cylinder Block - Inspect" for
the correct procedure. Install the cylinder head. Refer to Disassembly
and Assembly, "Cylinder Head - Install".

dealer.
Troubleshooting C4.4 Marine Generator Set-Battery Problem

034- Battery Problem
Probable Causes
 Charging circuit
 Battery
 Auxiliary device
Recommended Actions
Table 1
Result: The charging circuit is not OK.

1. Charging Circuit
Charging Repair the charging circuit, as necessary.
A. Check that the battery charging circuit is
circuit
operating correctly. Refer to
Result: The charging circuit is OK.
Troubleshooting, "Alternator Problem".

Result: The battery is not OK.

2. Battery
Replace the battery. Refer to the Operation and
A. Verify that the battery is no longer able Maintenance Manual, "Battery - Replace".
Battery
to hold a charge. Refer to Systems

Operation/Testing and Adjusting, "Battery - Result: The battery is OK.
Test".

Result: The battery has been drained by an

auxiliary device being left in the ON position.
Charge the battery. Verify that the battery is

able to maintain a charge. Refer to Systems
3. Auxiliary Device
Operation/Testing and Adjusting for the correct
Auxiliary
procedure.
A. Check if an auxiliary device has drained Device
the battery by being left in the ON position.
Result: The battery has not been drained by an

auxiliary device being left in the ON position.

dealer.

Troubleshooting C4.4 Marine Generator Set-Alternator Problem

035- Alternator Problem
Note: This symptom is not an electronic system fault.
Probable Causes
 Alternator drive belt and tensioner

 Alternator
 Charging circuit
Recommended Actions
Table 1
Result: The alternator drive belts are not in

good condition or the belt tension is incorrect.
If the alternator drive belts are worn or

1. Alternator Drive Belt and Tensioner
damaged, replace the belts. Refer to
Disassembly and Assembly for the correct
A. Inspect the condition of the alternator
procedure.
drive belt.
Drive belt If necessary, replace the automatic belt
B. Check the belt tension. Check the
tensioner. Refer to Disassembly and Assembly
automatic belt tensioner.
Note: Excessive belt tension can result in
Result: The alternator drive belts are in good
damage to the alternator.
condition and the belt tension is correct.


Result: The alternator is not operating

correctly.
2. Alternator
Repair the alternator or replace the alternator,
as necessary. Refer to Disassembly and
A. Verify that the alternator is operating
Assembly, "Alternator - Remove" and
correctly. Refer to Special Instruction,
Alternator Disassembly and Assembly, "Alternator - Install"
REHS0354, "Charging System
Troubleshooting" for the proper testing
procedures.
Result: The alternator is operating properly.


Result: The charging circuit is not operating

correctly.
Clean all connections and tighten all

3. Charging Circuit
connections. Replace any faulty parts.
Charging
A. Inspect the battery cables, wiring, and
circuit Result: The charging circuit is operating
connections in the charging circuit.
correctly.

dealer.

Troubleshooting C4.4 Marine Generator Set-Alternator Is Noisy

036- Alternator Is Noisy
Note: This symptom is not an electronic system fault.
Refer to Systems Operation, Testing and Adjusting for information on possible electrical causes of this
condition.
Probable Causes
 Alternator drive belt and tensioner

 Alternator mounting bracket
 Alternator drive pulley
 Alternator bearings
Recommended Actions
Table 1
Result: The alternator drive belt is in

good condition and the belt tension is
correct.
Result: The alternator drive belts are

1. Alternator Drive Belt and Tensioner not in good condition or the belt tension
is incorrect.
A. Inspect the condition of the alternator drive
belt. If the alternator drive belts are worn or
damaged, replace the belts. Refer to
Drive belt
B. Check the belt tension. If necessary, check Disassembly and Assembly for the

the automatic belt tensioner. correct procedure.
Note: Excessive belt tension can result in If necessary, replace the automatic belt
damage to the alternator. tensioner. Refer to Disassembly and
Assembly for the correct procedure.
Result: The alternator drive belts are in

good condition and the belt tension is
correct.

2. Alternator Mounting Bracket Alternator Result: The alternator mounting bracket

Mounting is cracked and distorted.
A. Inspect the alternator mounting bracket for Bracket
cracks and distortion. Repair the mounting bracket or replace
the mounting bracket.
Note: The repair/replacement will

ensure that the alternator drive belt and
the alternator drive pulley are in
alignment.
Result: The alternator mounting bracket
is OK.

Result: There is excessive wear on the

alternator drive pulley.
Replace the pulley.

3. Alternator Drive Pulley
Result: The alternator drive pulley nut
A. Check the condition of the alternator drive Alternator was loose.
pulley. Look for deep grooves that have been Drive Pulley
worn into the pulley by the belt. Check that the Tighten the nut.
nut for the pulley has not become loose.
Result: There is not excessive wear on
the alternator drive pulley.

Result: The alternator bearings are not

OK.
Repair the alternator or replace the

alternator, as needed. Refer to
4. Alternator Bearings
Disassembly and Assembly for the
Alternator correct procedure.
A. Check the alternator bearings for signs of
bearings
wear.

Result: The alternator bearings are OK.

a Cat dealer.

Troubleshooting C4 4 Marine Generator Set

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TROUBLESHOOTING C4.

Measuring Fuel Dilution

 Gas chromatograph fuel dilution test

Minimum Oil Viscosity at 100 °C with Fuel Dilution

Verifying Fuel Dilution

 Fuel injector seals

Troubleshooting Test Steps Values Results

Result: Injector seals are damaged.

Result: A fuel injector is damaged.

Replace the fuel injector. Refer to Disassembly and