Localización y Solución de Problemas

3126B Engines for the IT62G Series II Integrated Toolcarrier and for the 950G Series
II and 962G Series II Wheel Loaders
Número de medio -SENR9617-05Fecha de publicación -01/07/2010 Fecha de actualización -28/07/2010

i02378515

Engine Cranks but Will Not Start

SMCS - 1000-035

Probable Causes
 Diagnostic codes, event codes, and the power supply for the Electronic Control
Module (ECM)
 Air inlet heater
 Engine shutdown switches
 Engine speed/timing
 Injection actuation pressure
 Unit injectors
 Fuel supply
 Combustion

Recommended Actions
Diagnostic Codes, Event Codes, and ECM Power Supply

Certain diagnostic codes and/or event codes may prevent the engine from starting. Connect
the Caterpillar Electronic Technician (ET) and check for active codes and/or for logged
codes. Troubleshoot any codes that are present before continuing with this procedure.

Note: If Cat ET will not communicate with the ECM, the problem is most likely with the
electrical power supply to the ECM. Refer to Troubleshooting, "Electrical Power Supply
Circuit - Test".

Air Inlet Heater

Ensure that the air inlet heater is working properly. Ensure that the heater element is in
good repair. For additional information on the air inlet heater, refer to Troubleshooting, "Air
Inlet Heater Circuit - Test".

Engine Shutdown Switches

The engine shutdown switches should be in the RUN position. Use Cat ET to verify the
status of the shutdown switches. When a shutdown occurs, the shutdown switch must be
reset prior to restarting the engine. On some applications, the keyswitch must be cycled
before the ECM will allow engine cranking. Allow the keyswitch power to the ECM to be
in the OFF position for at least 15 seconds prior to restarting the engine.

Note: If Cat ET will not communicate with the ECM, the problem is most likely with the
electrical power supply to the ECM. Refer to Troubleshooting, "Electrical Power Supply
Circuit - Test".

Engine Speed/Timing

1. Crank the engine and observe the engine speed on the Cat ET status screen. If Cat
ET indicates zero rpm, refer to Troubleshooting, "Engine Speed/Timing Sensor
Circuit - Test".

Note: 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.

2. Ensure that the timing reference gear is installed correctly. The engine will not start
if the gear was installed backward. Check for proper orientation between the
crankshaft and camshaft drive gears. Correct the orientation and/or replace the drive
gear, if necessary. Refer to the Disassembly and Assembly for information that
relates to the correct installation of the front gear train.

Injection Actuation Pressure

1. Check the engine oil level. Engine oil supplies the injection actuation pressure
circuit. The engine oil must be kept at the proper level for fuel injection.

2. If service has recently been performed on the engine, air may be present in the
injection actuation pressure circuit. Allow the engine to fully warm up and operate
the engine under load in order to purge the air from the injection actuation pressure
circuit.

3. Check the injection actuation pressure. Refer to Troubleshooting, "Injection

Actuation Pressure - Test" for the correct procedure.
 4. Check the operation of the injection actuation pressure control valve. Refer to
Troubleshooting, "Injection Actuation Pressure Control Valve Circuit - Test" for the
proper troubleshooting procedure.

Unit Injectors

Perform the "Injector Solenoid Test" on Cat ET in order to determine if each of the injector
solenoids are being energized by the ECM. Refer to Troubleshooting, "Injector Solenoid
Circuit - Test" for additional information.

Fuel Supply

1. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only. If
necessary, add fuel to the fuel tank. If the engine has been run out of fuel, it will be
necessary to purge the air from the fuel system. Refer to Operation and Maintenance
Manual, "Fuel System - Prime" for the correct procedure.

2. Check the fuel lines for the following problems: restrictions, collapsed lines and
pinched lines. If problems are found with the fuel lines, repair the lines and/or
replace the lines.

3. Check the fuel tank for debris or foreign objects which may block the fuel supply.

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.

4. Prime the fuel system if any of the following procedures have been performed:
o Replacement of the fuel filters

o Service on the low pressure fuel supply circuit

o Replacement of unit injectors

Note: A sight glass in the low pressure supply line is helpful in diagnosing air in the
fuel. Refer to Testing and Adjusting for more information.

5. Check fuel quality. Cold weather adversely affects the characteristics of the fuel.
Refer to the applicable Operation and Maintenance Manual for information on
improving the characteristics of the fuel during cold weather operation.

6. Check the filtered fuel pressure while the engine is being cranked. Refer to Testing
and Adjusting for the correct pressure values. If the fuel pressure is low, replace the
 fuel filters. If the fuel pressure is still low, check the following items: fuel transfer
pump, fuel transfer pump coupling and fuel pressure regulating valve. Refer to
Testing and Adjusting for more information.

Combustion

Check for combustion problems.

Localización y Solución de Problemas

3126B Engines for the IT62G Series II Integrated Toolcarrier and for the 950G Series
II and 962G Series II Wheel Loaders

Número de medio -SENR9617-05Fecha de publicación -01/07/2010 Fecha de actualización -28/07/2010

i05899181

Engine Will Not Crank

SMCS - 1000-035

Probable Causes
 Engine shutdown switches (if applicable)
 Circuit breakers
 Battery cables
 Batteries
 Starting circuit
 Flywheel ring gear
 Driven equipment
 Engine accessories
 Hydraulic cylinder lock
 Internal engine problem

Recommended Actions
Table 1

Troubleshooting Test Steps Values Results

1. Check the Engine Shutdown
Switches (If Applicable)

A. The engine shutdown switches should

be in the OFF position. Ensure that the
shutdown switches are in the correct
Result: The shutdown switches
position by verifying with Caterpillar
are OK.
Electronic Technician (ET).
Proceed to Test Step 2.
B. When a shutdown occurs, the
Shutdown
Electronic Control Module (ECM) must
Switches Result: The shutdown switch is
be powered down for at least 15 seconds
NOT OK.
prior to attempting to start the engine.
Repair: Perform the necessary
If Cat ET will not communicate with the
repairs and return to service.
Electronic Control Module (ECM), the
problem is most likely with the electrical
power supply to the ECM. Refer to the
diagnostic functional test
Troubleshooting, "Electrical Power
Supply Circuit - Test".

Result: The circuit breaker has

not tripped and is in good
working condition.

Proceed to Test Step 2.

Result: The circuit breaker has

2. Check the Circuit Breakers tripped and/or is not in good
working condition.
Circuit Breaker
A. Check the state of each of the circuit
breakers. Repair: Reset the circuit
breakers if the circuit breakers
are tripped. Prior to returning
the engine to service, determine
the condition that caused the
circuit breaker to trip. Perform
the necessary repairs and return
to service.
3. Inspect the Battery Cables and/or
Batteries Result: The batteries, battery
disconnect switch, bus bars,
A. Inspect the battery disconnect switch, battery posts, and battery cables
bus bars, battery posts, and battery are corrosion free and working
cables for loose connections and properly.
corrosion.
Proceed to Test Step 3.
B. Inspect the batteries.
Battery
Result: The batteries, battery
C. Charge the batteries, if necessary. disconnect switch, bus bars,
Refer to Special Instruction , REHS7633, battery posts, and battery cables
"Battery Test Procedure". have corrosion and are not
working properly.
D. Load test the batteries. Refer to
Special Instruction, SEHS9249, "Use of Repair: Perform the necessary
4C-4911 Battery Load Tester for 6, 8, repairs and return to service.
and 12 V Lead Acid Batteries."

Result: The operation of the

starting motor and associated
circuit components are
functionally correctly.

Proceed to Test Step 5.

4. Check the Starting Circuit
Result: The operation of the
Starting Circuit starting motor and associated
A. Test the operation of the starting
circuit components are not
motor and associated circuit components.
functionally correctly.

Repair: Perform the necessary

repairs and return to service.
Refer to the Systems Operation
and Testing and Adjusting
manual.

5. Check the Driven Equipment Driven Result: The driven equipment

and/or Engine Accessories Equipment and/or engine accessories are
and/or Engine properly working.
A. Ensure free movement of the Accessories
driveline. Proceed to Test Step 6.
B. Ensure that timing pin was not left in
the flywheel housing.

C. Remove any engine accessories that

Result: The driven equipment
may lock up the engine.
and/or engine accessories are
not properly working.
D. Inspect the condition of the
accessories. The following list illustrates
Repair: Perform the necessary
examples of engine accessories that may
repairs and return to service.
lock up the engine:
If the problem is not resolved,
- Fuel transfer pump
proceed to the nest step.
- Air compressor

- Engine oil pump

6. Check for Hydraulic Cylinder Lock
A. Check for fluid in the cylinders
(hydraulic cylinder lock) by removing
the individual unit injectors. Be sure to Hydraulic
drain the fuel from the cylinder head
prior to removing the injectors. Fuel will
flow from the cylinder head into the
cylinders when the unit injector is
removed.
Result: The engine does not
have a hydraulic cylinder lock.
Proceed to Test Step 7.
Cylinder Lock Result: The engine does have a
hydraulic cylinder lock.
Repair: Perform the necessary
repairs and return to service.

7. Check for an Internal Engine Mechanical Result: There is no internal

Problem Problem engine problem.

A. If a mechanical problem is suspected, Result: The engine has an

disassemble the engine. Refer to the internal engine problem.
Disassembly and Assembly manual.
Repair: Repair or replace any
B. Inspect the internal components for worn parts. Refer to the
the following conditions: Disassembly and Assembly
manual.
- Seizure

- Broken Components
- Bent Components

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Todos los derechos reservados.
Red privada para licenciados del SIS.

Fuel System Pressure - Test

SMCS - 1250-081; 1256-081

Table 1

Tools Needed

Part Number Part Name Quantity

1U-5470 Engine Pressure Group 1

or or
198-4240 Digital Pressure Indicator

3Y-2888 Connector 1

3J-1907 O-Ring Seal 1

Note: Both the 5P-2720 Probe Adapter Gp and the 164-2192 Pressure Probe can be used with
these tools. Use these additional tools to allow the future installation of pressure probes.

Fuel leaked or spilled onto hot surfaces or electrical components can

cause a fire. Clean up fuel spills immediately.

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
 NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

The 1U-5470 Engine Pressure Group or the 198-4240 Digital Pressure Indicator can be
used in order to check the engine's fuel pressures.

Refer to Special Instruction, SEHS8907, "Using the 1U-5470 Engine Pressure Group " for
the instructions that are needed to use the 1U-5470 Engine Pressure Group. Refer to
Operation Manual, NEHS0818, "Using the 198-4240 Digital Pressure Indicator " for the
instructions that are needed to use the 198-4240 Digital Pressure Indicator.

Ver imagen

Illustration 1 g01140172

The fuel pressure should be in the following range when the engine is under normal
operating conditions and the engine is under load:
  400 to 525 kPa (58 to 76 psi)

At low idle, the fuel pressure at the fuel filter's inlet should be at the following amount:

 400 to 435 kPa (58 to 64 psi)

The fuel pressure to the passage for fuel supply should be the same amount, if you subtract
the change in pressure (delta P) across the filter.

With a new filter, the pressure drop across the fuel filter typically registers the following
amount:

 35 kPa (5 psi)

As abrasive particles collect in the fuel filter, the pressure differential across the filter will
increase. When a filter becomes plugged, fuel supply pressure may drop as low as 69 kPa
(10 psi) before a significant power loss is detected by the operator. Low fuel pressure will
cause cavitation and internal damage to the unit injectors. The pressure differential across
the fuel filter should not exceed 69 kPa (10 psi).

To check the filtered fuel pressure, follow this procedure:

1. Remove the plug (1) from the fuel filter base.

2. Install the connector, the seal, and the engine pressure test group into port (1) in the
fuel filter base. Refer to Special Instruction, SEHS8907, "Using the 1U-5470
Engine Pressure Group ".