Cat 3500B Generator Set Engines Troubleshooting Manual – PDF DOWNLOAD

Description

Cat 3500B Generator Set Engines Troubleshooting Manual – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Cat 3500B Generator Set Engines Troubleshooting Manual – PDF DOWNLOAD

Troubleshooting Section
Electronic Troubleshooting

Electronic Controls
Electronic Control Module

The ECM supplies signals to the Electronic Unit Injectors. The ECM signals control the engine operation. The ECM consists of two main components, the control computer (hardware) and the Personality Module (software).

• The control computer consists of a microprocessor and electronic circuitry. The Personality Module is the software for the control computer which contains operating maps that define power and torque curves.
• The ECM governs engine speed. Desired engine rpm is determined by the throttle position sensor signal and certain sensor readings. Diagnostic codes may derate the engine. Actual engine rpm is determined by the Engine Speed/Timing signal.

Fuel Injection :

The ECM controls the timing of the injectors. The ECM varies the signals to the injectors. Fuel is injected ONLY while an injector solenoid is energized by a 105 volt signal from the ECM. By controlling the timing and duration of the 105 volt signal, the ECM controls the fuel injection timing, the quantity of fuel and the desired engine rpm.

• Injection timing depends on engine rpm, load, and other operational factors. The ECM detects the top center of each cylinder. The ECM sends an injection signal at the desired time. The ECM limits engine power during cold mode operation. The ECM modifies the injection timing and the ECM cuts out the cylinders. This will increase startability and this will reduce warm up time.
• Cold Mode is activated whenever the engine coolant temperature falls below a predetermined value. Cold Mode remains active until the engine has warmed or a time limit is exceeded. The ECM is programmed at the factory which limits the quantity of fuel that can be injected. The FRC Fuel Position controls the fuel limit for exhaust smoke.
• The FRC is based on the maximum allowable fuel to air ratio. The FRC Fuel Position is increased when the ECM senses a higher Turbocharger Compressor Outlet Pressure. This will allow more fuel into the cylinder.
• The Rated Fuel Position is a limit that is based on the engine power rating. This is similar to the rack stops and the torque spring on a mechanically governed engine. The Rated Fuel Position provides power. The Rated Fuel Position provides the power curves and the torque curves for a specific engine family.

TABLE OF CONTENTS:

Cat 3500B Generator Set Engines Troubleshooting Manual – PDF DOWNLOAD

Troubleshooting Section
Electronic Troubleshooting
System Overview 6
Self-Diagnostics 13
Electronic Service Tools 14
Electronic Display Module 17
Engine Monitoring System 18
Programming Parameters
Programming Parameters 23
Factory Passwords 23
Flash Programming 23
System Configuration Parameters 24
Factory Passwords Worksheet 26
Customer Parameters Worksheet 27
Replacing the ECM 28
Troubleshooting without a Diagnostic Code
Symptoms 31
Alternator 31
Can Not Reach Top Engine RPM 31
Coolant in Engine Oil 32
Coolant Temperature Is Too High 32
ECM Will Not Accept Factory Passwords 33
ECM Will Not Communicate with Other Systems or
Display Modules 33
Electronic Service Tool Will Not Communicate with
ECM 34
Engine Cranks but Will Not Start 34
Engine Has Early Wear 35
Engine Misfires, Runs Rough or Is Unstable 36
Engine Oil in Cooling System 37
Engine Stalls at Low RPM 37
Engine Will Not Crank 37
Excessive Engine Oil Consumption 38
Excessive Black Smoke 39
Excessive White Smoke40
Exhaust Temperature Is Too High 41
Fuel Dilution of Engine Oil 41
Fuel in Cooling System 41
Intermittent Engine Shutdown 41
Intermittent Low Power or Power Cutout 42
Low Engine Oil Pressure 43
Low Power/Poor or No Response to Throttle 44
Mechanical Noise (Knock) in Engine 45
Noise Coming from Cylinder 45
Poor Fuel Consumption 46
Too Much Valve Lash 47
Too Much Vibration 47
Valve Rotocoil or Spring Lock Is Free 48 ·
Troubleshooting with a Diagnostic Code
Diagnostic Codes49
MID 036 – CID 0001 – FMI 05 Injector Cylinder 1 open
circuit 50
MID 036 – CID 0001 – FMI 06 Injector Cylinder 1
short···································································· 50
3
Table of Contents
MID 036 – CID 0002 – FMI 05 Injector Cylinder 2 open
circuit 51
MID 036 – CID 0002 – FMI 06 Injector Cylinder 2
short 51
MID 036 – CID 0003 – FMI 05 Injector Cylinder 3 open
circuit 51
MID 036 – CID 0003 – FMI 06 Injector Cylinder 3
short 51
MID 036 – CID 0004 – FMI 05 Injector Cylinder 4 open
circuit 52
MID 036 – CID 0004 – FMI 06 Injector Cylinder 4
short 52
MID 036 – CID 0005 – FMI 05 Injector Cylinder 5 open
circuit 52
MID 036 – CID 0005 – FMI 06 Injector Cylinder 5
short 52
MID 036 – CID 0006 – FMI 05 Injector Cylinder 6 open
circuit 53
MID 036 – CID 0006 – FMI 06 Injector Cylinder 6
short 53
MID 036 – CID 0007 – FMI 05 Injector Cylinder 7 open
circuit 53
MID 036 – CID 0007 – FMI 06 Injector Cylinder 7
short 53
MID 036 – CID 0008 – FMI 05 Injector Cylinder 8 open
circuit 54
MID 036 – CID 0008 – FMI 06 Injector Cylinder 8
short 54
MID 036 – CID 0009 – FMI 05 Injector Cylinder 9 open
circuit 54
MID 036 – CID 0009 – FMI 06 Injector Cylinder 9
short 54
MID 036 – CID 0010 – FMI 05 Injector Cylinder 10
open circuit 55
MID 036 – CID 0010 – FMI 06 Injector Cylinder 10
short 55
MID 036 – CID 0011 – FMI 05 Injector Cylinder 11
open circuit 55
MID 036 – CID 0011 – FMI 06 Injector Cylinder 11
short 55
MID 036 – CID 0012 – FMI 05 Injector Cylinder 12
open circuit 56
MID 036 – CID 0012 – FMI 06 Injector Cylinder 12
short 56
MID 036 – CID 0013 – FMI 05 Injector Cylinder 13
open circuit 56
MID 036 – CID 0013 – FMI 06 Injector Cylinder 13
short 56
MID 036 – CID 0014 – FMI 05 Injector Cylinder 14
open circuit 57
MID 036 – CID 0014 – FMI 06 Injector Cylinder 14
short 57
MID 036 – CID 0015 – FMI 05 Injector Cylinder 15
open circuit 57
MID 036 – CID 0015 – FMI 06 Injector Cylinder 15
short 57
MID 036 – CID 0016 – FMI 05 Injector Cylinder 16
open circuit 58
MID 036 – CID 0016 – FMI 06 Injector Cylinder 16
short 58
MID 036 – CID 0091 – FMI 08 Throttle Position signal
abnormal 58
MID 036 – CID 0094 – FMI 02 Fuel Pressure
misinstalled 59
MID 036 – CID 0094 – FMI 03 Fuel Pressure
open/short to +batt 59
MID 036 – CID 0094 – FMI 04 Fuel Pressure short to
ground 59
MID 036 – CID 0094 – FMI 13 Fuel Pressure
calibration required 59
MID 036 – CID 0100 – FMI 02 Engine Oil Pressure out
of range 60
MID 036 – CID 0100 – FMI 03 Engine Oil Pressure
open/short to +batt 60
MID 036 – CID 0100 – FMI 04 Engine Oil Pressure
short to ground 60
MID 036 – CID 0100 – FMI 13 Engine Oil Pressure
calibration required 61
MID 036 – CID 0101 – FMI 03 Crankcase Pressure
open/short to +batt 61
MID 036 – CID 0101 – FMI 04 Crankcase Pressure
short to ground 61
MID 036 – CID 0101 – FMI 13 Crankcase Pressure
calibration required 62
MID 036 – CID 0110 – FMI 03 Engine Coolant
Temperature open/short to +batt 62
MID 036 – CID 0110 – FMI 04 Engine Coolant
Temperature short to ground 62
MID 036 – CID 0168 – FMI 00 System Voltage
High 62
MID 036 – CID 0168 – FMI 01 System Voltage
Low 63
MID 036 – CID 0168 – FMI 02 System Voltage
intermittent/erratic63
MID 036 – CID 0190 – FMI 02 Loss of Engine Speed
signal 63
MID 036 – CID 0190 – FMI 03 Engine Speed
open/short to +batt 63
MID 036 – CID 0190 – FMI 08 Engine Speed signal
abnormal 64
MID 036 – CID 0248 – FMI 09 CAT Data Link
Communications 64
MID 036 – CID 0253 – FMI 02 Personality Module
mismatch 64
MID 036 – CID 0254 – FMI 12 Electronic Control
Module Error 64
MID 036 – CID 0261 – FMI 13 Engine Timing
calibration required 65
MID 036 – CID 0262 – FMI 03 5 Volt Sensor Supply
short to +batt 65
MID 036 – CID 0262 – FMI 04 5 Volt Sensor Supply
short to ground 65
MID 036 – CID 0263 – FMI 03 Digital Sensor Supply
short to +batt 65
MID 036 – CID 0263 – FMI 04 Digital Sensor Supply
short to ground 66
MID 036 – CID 0268 – FMI 02 Check Programmable
Parameters 66
MID 036 – CID 0273 – FMI 00 Turbo Outlet Pressure
above normal 66
MID 036 – CID 0273 – FMI 03 Turbo Outlet Pressure
open/short to +batt 67
MID 036 – CID 0273 – FMI 04 Turbo Outlet Pressure
short to ground 67
MID 036 – CID 0273 – FMI 13 Turbo Outlet Pressure
calibration required 67
MID 036 – CID 0274 – FMI 03 Atmospheric Pressure
open/short to +batt 67
MID 036 – CID 0274 – FMI 04 Atmospheric Pressure
short to ground 68
MID 036 – CID 0274 – FMI 13 Atmospheric Pressure
calibration required 68
MID 036 – CID 0275 – FMI 03 Right Turbo Inlet
Pressure open/short to +batt 68
MID 036 – CID 0275 – FMI 04 Right Turbo Inlet
Pressure short to ground 69
MID 036 – CID 0275 – FMI 13 Right Turbo Inlet
Pressure calibration required 69
MID 036 – CID 0276 – FMI 03 Left Turbo Inlet
Pressure open/short to +batt 69
MID 036 – CID 0276 – FMI 04 Left Turbo Inlet
Pressure short to ground 70
MID 036 – CID 0276 – FMI 13 Left Turbo Inlet
Pressure calibration required 70
MID 036 – CID 0279 – FMI 03 Aftercooler Temperature
open/short to +batt 70
MID 036 – CID 0279 – FMI 04 Aftercooler Temperature
short to ground 71
MID 036 – CID 0289 – FMI 02 Unfiltered Fuel Pressure
misinstalled 71
MID 036 – CID 0289 – FMI 03 Unfiltered Fuel Pressure
open/short to +batt 71
MID 036 – CID 0289 – FMI 04 Unfiltered Fuel Pressure
short to ground 72
MID 036-CID 0289- FMI 13 Unfiltered Fuel Pressure
calibration required 72
MID 036 – CID 0336 – FMI 02 Incorrect ECS Switch
inputs 72
MID 036 – CID 0337 – FMI 02 Incorrect Remote
E-Stop Switch inputs 72
MID 036 – CID 0338 – FMI 05 Pre-Lube Relay open
circuit 73
MID 036 – CID 0338 – FMI 06 Pre-Lube Relay short
to ground 73
MID 036 – CID 0444 – FMI 05 Start Relay open
circuit 73
MID 036 – CID 0444 – FMI 06 Start Relay short to
ground 73
MID 036 – CID 0446 – FMI 05 Air Shutoff Relay
open 74
MID 036 – CID 0446 – FMI 06 Air Shutoff Relay
short 74
MID 036 – CID 0542 – FMI 02 Unfiltered Engine Oil
Pressure misinstalled 74
MID 036 – CID 0542 – FMI 03 Unfiltered Engine Oil
Pressure open/short to +batt 74
MID 036 – CID 0542 – FMI 04 Unfiltered Engine Oil
Pressure short to ground 75
MID 036 – CID 0542 – FMI 13 Unfiltered Engine Oil
Pressure cal required 75
MID 036 – CID 0545 – FMI 05 Ether Start Relay
open/short to +batt 75
MID 036 – CID 0545 – FMI 06 Ether Start Relay short
to ground 75
MID 036 – CID 0546 – FMI 05 Ether Hold Relay
open/short to ground 76
MID 036 – CID 0546 – FMI 06 Ether Hold Relay short
to +batt 76
MID 036 – CID 0827 – FMI 08 Left Exhaust
Temperature signal abnormal 76
MID 036 – CID 0828 – FMI 08 Right Exhaust
Temperature signal abnormal 76
Diagnostic Functional Tests
Air Shutoff System 78
Analog Sensor Supply 82
CAT Data Link 87
Digital Sensor Supply 91
Direct Fuel Control Mode , 93
ECM/Personality Module 96
Electrical Power Supply 98
Emergency Stop Switch1 02
Engine Control Switch (ECS) 104
Engine Sensor Open/Short Test 108
Engine Speed/Timing Sensor 116
Ether Injection System 121
Injector Solenoids 128
Inspecting Electrical Connectors 134
Prelubrication System138
Speed Control 143
Starting Motor System 147
Calibration Procedures
Analog Sensor – Calibrate 151
Engine Speed/Timing Sensor – Calibrate 152
Index Section
Index 154

CAT 3500B GENERATOR SET ENGINES TROUBLESHOOTING MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
• No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
• Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
• So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com

S.V