Troubleshooting Caterpillar 3612 and 3616 (2)

Troubleshooting Caterpillar 3612 and 3616 Engines

Caterpillar 3616

Low Power
Probable Cause
1. Dirty fuel filters
If the pressure differential between the inlet port of the fuel filter housing and the outlet port of the fuel filter housing is 70 kPa (10 psi), replace the filter.
2. Low quality fuel or water in fuel
Remove the fuel from the fuel tank. Install new fuel filters. Put a good grade of clean fuel in the fuel tank. Refer to Caterpillar 3600 Series Diesel Engine Fluids Recommendations For Lubricants, Fuels, and Coolants,SEBU7003.
3. High fuel temperature
If the fuel supply temperature is 38 °C (100°F) or more, a fuel cooler may be necessary.
Return fuel serves to remove heat from the fuel injectors. A fuel cooler is recommended in order to prevent excessive power loss and a fuel cooler is recommended in order to maintain an acceptable injector life.
4. Low fuel pressure
The fuel pressure at the outlet of the fuel filter housing must be a minimum of 450 kPa (65 psi) at full load speed. If fuel pressure is lower than the above pressure, install new fuel filter elements. If the fuel pressure is still low, check the fuel transfer pump.
Make sure that there is fuel in the fuel tank. Look for leaks or bends in the fuel line between the fuel tank and the fuel transfer pump. Look for air in the fuel system. Also look for a faulty return fuel pressure regulating valve.
5. Faulty fuel injector
Refer to "Misfire or Running Rough".
6. Leaks in air inlet system
Check the pressure in the air inlet manifold (plenum). Look for leak paths in the air cleaner pipe assemblies and the clamped joints.
7. Governor and fuel control linkage
Ensure that the governor is moving the fuel control linkage against the fuel setting stop. Make adjustment in order to get the full travel of the linkage. Install new parts for those parts that have damage or defects. If the control linkage is not against the stop and the engine runs below rated speed under load, perform the following inspections:
a. Check high idle and adjust, if necessary.
b. The fuel ratio control may be restricting the travel of the control linkage. Adjust, If necessary.
8. Wrong valve lash
Adjust the valve lash. Refer to System Operation/Testing and Adjusting, "Valve Lash and Valve Bridge Adjustment".
9. Wrong fuel injection timing
Adjust the timing. Refer to System Operation/Testing and Adjusting, "Fuel Timing".
10. Incorrect fuel setting
Adjust the timing. Refer to System Operation/Testing and Adjusting, "Fuel Setting".
11. Ineffective aftercooler
Check temperature of inlet and outlet coolant supply. Remove any external restrictions or internal restrictions.
12. Carbon deposits on turbocharger or other causes of friction
Inspect the turbocharger. Repair the turbocharger, if necessary. Check for low boost pressure. Low boost pressure is ten percent below initial boost pressure.
13. Not enough air for combustion
Check the air cleaner for restrictions and check the aftercooler for restrictions.

Excessive Vibration
Probable Cause
1. Loose vibration damper
Inspect the vibration damper for damage. Tighten the bolts, if necessary. If the vibration damper bolt holes have damage or wear, replace the vibration damper's hub.
2. Faulty vibration damper
Inspect the vibration damper for leakage and inspect the vibration damper for a damaged case assembly. Either of the above conditions can cause the weight to come into contact with the housing. If the weight contacts the housing, the operation of the vibration damper is affected. Perform a torsional vibration measurement.
3. Engine supports are loose or faulty.
Tighten all mounting bolts. Install new components, if necessary.
4. Driven equipment is not in alignment or driven equipment is not in balance.
Check alignment and balance. Correct alignment and balance, if necessary.
5. Misfiring or running rough.
Refer to "Misfire or Running Rough".
6. External causes of vibration
Check the equipment in the engine and around the engine for the source of the vibration.

Combustion Noise (Knock)
Probable Cause
1. Wrong fuel injection timing
Adjust the timing. Refer to System Operation/Testing and Adjusting, "Fuel Timing".
2. Defect in fuel injector
Refer to "Misfire or Running Rough".

Valve Train Noise (Clicking)
Probable Cause
1. Damage to valve train components
Inspect all of the following valve train components:
Valves
Springs
Camshafts
Lifters
Rocker arms
Pushrods
Check for worn parts or damaged parts. Replace worn parts or damaged parts, as required.
2. Insufficient lubrication
Check the lubrication in the valve compartment. There must be a strong flow of oil at engine high rpm. There must be a small flow of oil at low rpm. Oil passages must be clean. The oil passages that send the oil to the cylinder head are particularly important.
3. Too much valve lash
Make adjustment to valve lash. Refer to System Operation/Testing and Adjusting, "Valve Lash and Valve Bridge Adjustment".

Loud Valve Train Noise
Probable Cause
1. Damage to valve springs
Replace the damaged components.
2. Damage to camshaft
Replace the damaged components. Clean the engine thoroughly. If the camshaft is replaced, new valve lifters are necessary.
3. Damage to valve lifter
Clean the engine thoroughly. Replace the damaged valve lifters. Inspect the lobes of the camshaft for damage.
Look for valves that do not move freely. Adjust the valve lash. Refer to System Operation/Testing and Adjusting, "Valve Lash and Valve Bridge Adjustment".

Oil in the Cooling System
Probable Cause
1. Defect in core of engine oil cooler
Inspect each engine oil cooler. Repair any faulty oil cooler or replace any faulty oil cooler, as required.
2. Failure of cylinder head water seals
Install new cylinder head water seals in the seal plates.
3. Faulty water pump seal
Check the water pump. If necessary, repair the water pump.

Mechanical Noise (Knock)
Probable Cause
1. Failure of bearing for connecting rod
Inspect the bearings for the connecting rods and the bearing surfaces (journals) on the crankshaft. Install new
parts, as required.
2. Damaged gears
Install new parts, as required.
3. Damaged crankshaft
Replace the crankshaft.
4. Defect in accessory equipment
Repair the faulty components or install new components.
5. Wrong adjustment of fuel injector
Adjust the fuel injector.
6. Wrong adjustment of valve bridge
Adjust valves and valve bridges. Refer to System Operation/, "Valve Lash and Valve Bridge Adjustment".

Excessive Fuel Consumption
Probable Cause
1. Fuel system leaks
Tighten or replace of parts at points of leakage.
2. Fuel and combustion noise (knock)
Refer to "Combustion Noise (Knock)".
3. Wrong fuel injection timing
Make adjustment to timing. Refer to System Operation/Testing and Adjusting, "Fuel Timing".
4. Defect in fuel injectors
Refer to "Misfire or Running Rough"
5. Low quality fuel or water in fuel
Remove the fuel from the fuel tank. Install new fuel filters. Put a good grade of clean fuel in the fuel tank. Refer to Caterpillar 3600 Series Diesel Engine Fluids Recommendations For Lubricants, Fuels, and Coolants, SEBU7003.
6. Incorrect high idle
Adjust high idle setting.
7. Overloaded engine
Do not exceed recommended capacities.
8. Excessive exhaust back pressure
Refer to System Operation/Testing and Adjusting, "Air Inlet and Exhaust System".

Valve lash
Probable Cause
1. Not enough lubrication
Check the lubrication in the valve compartment. There must be a strong flow of oil at engine high rpm. There must be a small flow of oil at low rpm. Oil passages must be clean. The oil passages that send the oil to the cylinder head are particularly important.
2. Worn rocker arm
If the face of the rocker arm that makes contact with the valve bridge has too much wear, install new parts or rocker arms. Adjust to valve lash. Refer to System Operation/Testing and Adjusting, "Valve Lash and Valve Bridge Adjustment".
3. Worn valve bridges
Adjust or replace, as required.
4. Worn valve stem
If the end of the valve stem has too much wear, install new valves. Adjust the valve lash. Refer to System Operation/Testing and Adjusting, "Valve Lash and Valve Bridge Adjustment".
5. Worn pushrods
If the pushrods have too much wear, install new pushrods. Adjust the valve lash. Refer to System
Operation/Testing and Adjusting, "Valve Lash and Valve Bridge Adjustment".
6. Broken valve lifters or worn valve lifters
Install new valve lifters. Check the camshaft for wear. Check for free movement of valves or bent valve stem.
Clean the engine thoroughly. Adjust the valve lash. Refer to System Operation/Testing and Adjusting, "Valve Lash and Valve Bridge Adjusment".
7. Worn camshaft
Check valve lash. Check for wear on camshaft lobes. Check for free movement of valves or bent valve stems.
Install a new camshaft. Install new valve lifters. Adjust the valve lash. Refer to System Operation/Testing and
Adjusting, "Valve Lash and Valve Bridge Adjusment".

The Valve Rotocoil is Free or Spring Lock is Free
Probable Cause
1. Broken locks
Broken locks can cause the valve to slide into the cylinder. This will cause much damage.
2. Broken valve spring
Install a new valve spring.
3. Broken valve
Replace the valve and the other damaged parts.

Oil in the Exhaust
Probable Cause
1. Too much oil in the valve compartment
Be sure that the plugs are installed in the ends of the rocker arm shaft.
2. Worn valve guides
Reconditioning of the cylinder head is required.
3. Worn piston rings
Inspect piston rings and install new parts, as required.
4. Excessive idle time
Do not idle the engine for long time periods.

troubleshooting caterpillar 3612 & 3616

CAT SENR3593 - 3612 and 3616 Engines