Caterpillar Troubleshooting 3516B and 3516B High Displacement Engines for Caterpillar Built Machines

FDB1-Up (Machine)
8WM1-Up (Engine)
7TR1-Up (Engine)

Table of Contents
Troubleshooting Section
Electronic Troubleshooting
System Overview ……………………………………………. 4
Self-Diagnostics …………………………………………….. 11
Electrical Connectors and Functions ……………….. 12
Electronic Service Tools …………………………………. 14
Diagnostic Code List ……………………………………… 16
Event Code List ……………………………………………. 21
Programming Parameters
Programming Parameters ………………………………. 28
Factory Passwords ……………………………………….. 28
Factory Passwords Worksheet ……………………….. 28
Flash Programming ………………………………………. 29
System Configuration Parameters …………………… 30
Customer Parameters Worksheet …………………… 33
Replacing the ECM ……………………………………….. 34
Troubleshooting without a Diagnostic Code
Symptoms ……………………………………………………. 36
Alternator (Noisy Operation) …………………………… 36
Boost Pressure Above Normal ……………………….. 37
Boost Pressure Below Normal ………………………… 37
Can Not Reach Top Engine RPM ……………………. 39
Coolant in Engine Oil …………………………………….. 40
Coolant Temperature Is Too Low …………………….. 40
Coolant Temperature Is Too High ……………………. 41
Crankcase Pressure (High) ……………………………. 42
ECM Will Not Accept Factory Passwords …………. 43
ECM Will Not Communicate with Other Systems or
Display Modules ………………………………………….. 43
Electronic Service Tool Will Not Communicate with
ECM ………………………………………………………….. 44
Engine Cranks but Will Not Start …………………….. 45
Engine Has Early Wear …………………………………. 46
Engine Misfires, Runs Rough or Is Unstable …….. 47
Engine Oil in Cooling System …………………………. 48
Engine Overspeed ………………………………………… 48
Engine Stalls at Low RPM ……………………………… 49
Engine Will Not Crank ……………………………………. 50
Excessive Engine Oil Consumption …………………. 51
Excessive Black Smoke …………………………………. 51
Excessive White Smoke ………………………………… 53
Exhaust Temperature Is Too High ……………………. 54
Fuel Dilution of Engine Oil ……………………………… 55
Fuel in Cooling System ………………………………….. 55
Inlet Air Restriction ………………………………………… 55
Intermittent Engine Shutdown …………………………. 56
Intermittent Low Power or Power Cutout ………….. 57
Low Engine Oil Pressure ……………………………….. 58
Low Power/Poor or No Response to Throttle ……. 59
Mechanical Noise (Knock) in Engine ……………….. 61
Noise Coming from Cylinder …………………………… 61
Poor Fuel Consumption …………………………………. 62
Too Much Valve Lash …………………………………….. 63
Too Much Vibration ……………………………………….. 64
Valve Rotocoil or Spring Lock Is Free ………………. 64
Diagnostic Functional Tests
Analog Sensor (Active) ………………………………….. 65
Cat Data Link ……………………………………………….. 73
Coolant Flow Switch ……………………………………… 76
Electrical Power Supply …………………………………. 80
Engine Oil Level Switch …………………………………. 85
Engine Oil Renewal Solenoid …………………………. 89
Engine Speed/Timing Sensor …………………………. 92
Ether Injection System …………………………………… 96
Fuel Filter Differential Pressure Switch …………… 106
Ground Level Shutdown Switch …………………….. 109
Injector Solenoids ………………………………………… 112
Inspecting Electrical Connectors …………………… 121
Prelubrication System ………………………………….. 126
Pulse Width Modulated Sensor …………………….. 133
Sensor Supply ……………………………………………. 138
Throttle Position Sensor ………………………………. 145
User Defined Shutdown Input ……………………….. 149
Wastegate Solenoid …………………………………….. 152
Calibration Procedures
Engine Speed/Timing Sensor – Calibrate ………… 157
Index Section
Index …………………………………………………………. 159

Download instantly this Manual from our website for the lowest price.

After sales you can contact us for any kind of discrepancy.

Also kindly contact us for any service manual or user manual requirements.