Cat 3500C Marine Propulsion Engines Troubleshooting Manual – PDF DOWNLOAD

Description

Cat 3500C Marine Propulsion Engines Troubleshooting Manual – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Cat 3500C Marine Propulsion Engines Troubleshooting Manual – PDF DOWNLOAD

TTA1-Up (Engine)
TTB1-Up (Engine)
M8C1-Up (Engine)
TTC1-Up (Engine)
M8D1-Up (Engine)
TTD1-Up (Engine)
TTE1-Up (Engine)
TTF1-Up (Engine)
TTG1-Up (Engine)
TTH1-Up (Engine)
TTJ1-Up (Engine)
E3W1-Up (Engine)
E3X1-Up (Engine)
E3Z1-Up (Engine)

Important Safety Information:

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

• Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.
• Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

Introduction
General Information
Electronic Control System

The electronic system consists of an Electronic Control Module (ECM), the wiring harness, switches, sensors, and fuel injectors. The ECM consists of two main components, the control computer (hardware) and the flash file (software). The control computer consists of a microprocessor and electronic circuitry. The flash file contains the engine’s operational characteristics. The operating maps define the following characteristics of the engine:

• Horsepower
• Torque curves
• Engine speed (rpm)
Refer to Troubleshooting, “System Overview” for additional information on the electronic control system.

TABLE OF CONTENTS:

Cat 3500C Marine Propulsion Engines Troubleshooting Manual – PDF DOWNLOAD

Troubleshooting Section
Introduction
General Information 4
Welding Precaution 4
Electronic Service Tools 5
Electronic System Overview
System Overview 8
Component Location 9
Electronic Display Module 12
Diagnostic Capabilities 14
Programmable Parameters 15
Electrical Connectors 16
Configuration Parameters
Configuration Parameters 19
Diagnostic Trouble Codes
Diagnostic Trouble Codes 24
Event Codes
Event Codes 29
Symptom Troubleshooting
Symptom Troubleshooting 35
Acceleration Is Poor or Throttle Response Is
Poor 35
Air Starting Motor Problem 37
Alternator Problem (Charging Problem and/or Noisy
Operation) 37
Coolant Contains Fuel 37
Coolant Contains Oil 38
Coolant Temperature Is High 39
Coolant Temperature Is Low 40
Crankcase Pressure Is High 41
Cylinder Is Noisy 42
ECM Does Not Communicate with Other
Modules 43
Engine Cranks but Does Not Start 43
Engine Does Not Crank 44
Engine Has Early Wear 45
Engine Has Mechanical Noise (Knock) 46
Engine Misfires, Runs Rough or Is Unstable 46
Engine Overspeeds 48
Engine Shutdown Is Intermittent 49
Engine Stalls at Low RPM 50
Engine Top Speed Is Not Obtained 51
Engine Vibration Is Excessive 52
Exhaust Has Excessive Black Smoke 53
Exhaust Has Excessive White Smoke 54
Exhaust Temperature Is High 55
Fuel Consumption Is Excessive 56
Fuel Filter Is Restricted 57
High Altitude Derate Occurrence 58
Inlet Air Is Restricted 59
Oil Consumption Is Excessive 59
Oil Contains Coolant 60
Oil Contains Fuel 60
Oil Filter Differential Pressure Problem 61
Oil Pressure Is Low 62
Power Is Intermittently Low or Power Cutout Is
Intermittent 64
Secondary ECM Assumes Control 65
Secondary ECM Indicator Lamp Problem 65
Synchronization Problem 66
Valve Lash Is Excessive 74
Valve Rotator or Spring Lock Is Free 75
Circuit Tests
Air Shutoff – Test 76
CAN Data Link – Test 85
Cat Data Link – Test 89
Electrical Power Supply – Test 93
Emergency Stop – Test 100
Emergency Stop (Remote) – Test 108
Engine Control Switch – Test 118
Injector Solenoid – Test 129
Prelubrication – Test 140
Sensor Signal (Analog, Active) – Test 151
Sensor Signal (Analog, Passive) – Test 160
Sensor Signal (PWM) – Test 165
Sensor Supply – Test 170
Speed Control (Switch) – Test 177
Speed/Timing – Test 184
Starting – Test 189
Service
Factory Passwords 201
ECM Will Not Accept Factory Passwords 201
Electronic Service Tool Does Not Communicate 201
ECM Software – Install 203
ECM – Replace 204
Electrical Connectors – Inspect 206
Pressure Sensor – Calibrate 209
Throttle Position Sensor – Calibrate 210
Timing – Calibrate 211
Index Section
Index

CAT 3500C MARINE PROPULSION ENGINES TROUBLESHOOTING MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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