Troubleshooting Caterpillar 3612 and 3616 (4)

Troubleshooting Caterpillar 3612 and 3616

Excessive White Smoke or Blue Smoke
Probable Cause
1. Too much lubrication oil in engine
Remove extra oil. Put the correct amount of oil in the engine.
2. Misfire or the running rough.
Refer to "Misfire or Running Rough".
3. Wrong fuel injection timing
Adjust the timing. Refer to System Operation/Testing and Adjusting, "Fuel Timing".
4. Worn valve guides
Reconditioning of cylinder head is required.
5. Worn piston rings or improperly installed piston rings
Inspect piston rings and install new parts, as required.
6. Failure of turbocharger oil seal
Check the air inlet manifold (plenum) for oil and repair the turbocharger, as required.
7. Faulty aftercooler core
Check aftercooler core for leaks.
8. Faulty valve lubricator pumps
Check the setting and the delivery of the valve lubricator pumps.
9. Worn cylinder liner
Check cylinder liners.

Low Oil Pressure
Probable Cause
1. Dirty oil filters or oil cooler
Check the operation of bypass valve for the oil filters. Install new oil filter elements. Clean oil cooler cores or install new oil cooler cores. Remove dirty oil from the engine. Clean centrifugal oil filters. Change engine oil.
2. Faulty oil pressure gauge
Install new gauge.
3. Diesel fuel in lubrication oil
Find the source of the leakage of the diesel fuel into the lubrication oil. Make repairs, as required. Remove the lubrication oil that has been contaminated with diesel fuel. Install new oil filters. Put clean oil in the engine.
4. Too much clearance between rocker arm shaft and rocker arms
Check lubrication in valve compartments. Install new parts, as required.
5. Faulty oil pump suction pipe
Replacement of oil pump suction pipe is required.
6. Oil pump's suction strainer is fouled.
Clean the strainer.
7. Faulty priority valve
Inspect the priority valve and replace damaged parts or worn parts.
8. Stuck open oil pressure relief valve
Clean the valve and the housing. Install new parts, as required.
9. Faulty oil pump
Repair the oil pump or replace the oil pump.
10. Too much clearance between crankshaft and crankshaft bearings
Inspect the crankshaft bearings and replace, as required.
11. Too much clearance between camshaft and camshaft bearings
Inspect the camshaft and the camshaft bearings. Replace the camshaft and the camshaft bearings, as required.
12. Loose oil plugs for crankshaft or missing oil plugs for crankshaft
Check the torque of the oil plugs for the crankshaft.
13. Loose plugs in rocker arm shaft or missing plugs from rocker arm shaft
Check plugs in the ends of the rocker arm shafts.
14. Loose oil supply line in box for lifter
Check the oil supply line from the cylinder block to the cylinder head behind the lifter assemblies.
15. Loose retainer on the idler gear for the rear gear train or missing retainer on the idler gear for the rear gear train
Check the retainer on the idler shafts of the rear gear train.

High Oil Pressure
Probable Cause
1. Restriction in engine lubrication system
Use pressure taps in order to determine the problem area and repair the problem area.
2. Faulty priority valve
Inspect the priority valve. Replace damaged parts or worn parts.
3. Faulty oil pressure relief valve
If necessary, inspect the oil pressure relief valve and repair the oil pressure relief valve.
4. Oil pump output too high.
Repair the oil pump or replace the oil pump.
5. Incorrect viscosity oil is used.
Drain the engine oil and refill the engine with oil of the correct viscosity. Install new oil filters.

Excessive Oil Consumption
Probable Cause
1. Too much lubrication oil in engine
Remove the extra oil. Put the correct amount of oil in the engine.
2. Oil leaks
Find all oil leaks. Make repairs, as required. Check for dirty crankcase breathers.
3. High oil temperature
Check operation of oil cooler and oil temperature regulator. Install new parts, as required. Clean the oil cooler cores.
4. Too much oil in the valve compartment
Be sure that the plugs are installed in the rocker shafts.
5. Worn valve guides
Reconditioning of the cylinder head is required.
6. Failure of turbocharger oil seal
Check the air inlet manifold (plenum) for oil and repair the turbocharger, as required.
7. Failure of crankshaft seal
Replace crankshaft seals.
8. Worn piston rings or improperly installed piston rings
Inspect piston rings and install new parts, as required.
9. Faulty valve for continuous prelube
Check operation of continuous prelube system.

Prelube Pump Inoperative or Slow
Probable Cause
1. Open circuit or grounded circuit on the electric motor
Inspect the wiring of the electric prelube pump and repair the wiring, as required.
2. Open circuit or grounded circuit on the solenoid
Inspect the wiring and repair the wiring, as required.
3. Low air pressure
Check the prelube pump's air system for air leaks. Check the air compressor for correct operation.
4. No lubrication to air motor
If necessary, repair the prelube pump's air system. If necessary, replace the air prelube pump's motor.

High Coolant Temperature
Probable Cause
1. Restriction of coolant flow through radiator core tubes
Clean the radiator or the heat exchanger and flush the radiator or the heat exchanger.
2. Low coolant level
Add coolant to the cooling system. Check for leaks.
3. Faulty pressure cap
Check operation of the pressure cap. Install a new pressure cap, as required.
4. Combustion gases in coolant
Find the source of the leakage of combustion gases into the cooling system. Make repairs, as required:
Cylinder liner
Water cooled valve seat insert
5. Faulty water temperature regulators
Check water temperature regulators for correct operation. Check the water temperature gauge for correct operation. Install new parts, as required.
6. Faulty jacket water pump
Repair the jacket water pump, as required.
7. Faulty aftercooler pump
Repairs the aftercooler pump, as required.
8. Too much load on the system
Reduce the load on the system.
9. Wrong fuel injection timing
Adjust the timing. Refer to System Operation/Testing and Adjusting, "Fuel Timing".
10. Incorrect coolant and/or flow
The system is not balanced correctly. Repair the system, as required.
11. Scale buildup
Clean the cooling system.

High Exhaust Temperature
Probable Cause
1. Inlet air leakage
Check the following locations and the associated piping for air leakage. If necessary, make the corrections.
O-ring seals between the compressor and the aftercooler
Air inlet shutoff
Plugged sections
Gaskets within aftercooler
Plenum
2. Leakage at exhaust system
Find the cause of the exhaust leak. Make repairs, as required.
3. Excessive exhaust restriction
Refer to System Operation/Testing and Adjusting, "Air Inlet and Exhaust System"
4. Insufficient air passage through filters or inlet air piping
Ensure that the air inlet restriction is less than 3.75 kPa (15 inches of H2O) when the filters and the piping are dirty.
5. Wrong fuel injection timing
If necessary, adjust the timing. Refer to System Operation/Testing And Adjusting, "Fuel Timing".
6. Faulty exhaust valve
Check exhaust valves for damage and replace exhaust valves, as required.
7. Faulty turbocharger
Inspect the turbocharger. Repair the turbocharger, if necessary. Check for low boost pressure. Low boost pressure is ten percent below initial boost pressure.
8. Fouled turbocharger
Ensure that both the compressor side and the turbine side of the turbocharger are not fouled.
9. The air inlet temperature is too high.
Refer to "High Air Inlet Temperature".
10. Excessive pressure drop through the aftercooler (air side)
Ensure that the air side of the aftercooler is not restricted or too contaminated with soot and debris.
Use the following guidelines in order to determine if a rise in exhaust temperatures is the result of a change in ambient conditions.
1. The exhaust manifold temperature will increase approximately 1.6 °C (2.90 °F) for every 1.0 °C (1.80 °F) increase in the inlet air temperature.
2. The exhaust manifold temperature will increase approximately 0.2 °C (0.36 °F) for every 1.0 °C (1.80 °F) increase in the aftercooler inlet water temperature.

High Oil Temperature
Probable Cause
1. Faulty oil temperature regulators
Check the oil temperature regulators for correct operation. Check the oil temperature gauge for correct
operation. Install new parts, as required.
2. Restriction of oil flow through the engine oil cooler
Clean the engine oil cooler and flush the engine oil cooler.
3. Engine coolant temperature is too high.
Refer to "High Coolant Ttemperature".
4. Low coolant flow
Refer to "High Coolant Temperature".
5. High crankcase pressure
Check for faulty main bearings and connecting rod bearings.

High Air Inlet Temperature
Probable Cause
Note: Inlet air temperatures should be compared to trends in the performance data in addition to data that is supplied by the factory. Do not rely on the setpoint of the alarm only. High inlet manifold temperature may occur on only the front half or the back half of the engine. This is due to a blockage that is only in one part of the water side of the aftercooler. When the inlet manifold temperature is being measured at the middle of the aftercooler, a hot front section or a hot back section can be undetected. This occurs because the temperature is taken at a point that yields an average temperature. Additional temperature measurements must be made at the ends of the inlet manifold.
1. Restriction of coolant flow through aftercooler cores
Clean the aftercooler cores and flush the aftercooler cores.
2. Engine coolant temperature is too high.
Refer to "High Coolant Temperature".
3. High ambient air temperature
Check the air temperature of the installation. Make sure that the ventilation is adequate.
Air Starting Motor
Probable Cause
1. Low air pressure
Check the system for leaks. Check the operation of the air compressor.
2. Faulty oil pressure valve (intermittent operation)
Check the operation of the oil pressure valve. Set the oil pressure valve to open at 7 kPa (1 psi). Replace the oil
pressure valve, as required.
3. Inoperative relay valve
Check the operation of the relay valve. Repair the relay valve or replace the relay valve, as required.
4. Faulty air start control valve
Repair the air start control valve or replace the air start control valve, as required.
5. Faulty air starting motor
Repair the air starting motor or replace the air starting motor, as required.
6. The pinion is not engaged.
Ensure that the pinion is engaged with the flywheel ring gear.
7. The manual barring group is engaged.
Check the manual barring group and the switches.
8. Fluid in the cylinders
Open the manual valves (Kiene valves). If the engine is not equipped with the manual valves, remove the cylinder pressure relief valve or plug. Inspect the cylinders for fluid while the crankshaft is being turned.

Air Starting Motor Turns Slowly or the Air Starting Motor has a Loss of Power
Probable Cause
1. Low air pressure
Check the system for leaks. Check the operation of the air compressor.
2. Malfunctioning lubricator
Check the lubricator for correct operation. Fill the lubricator and adjust the drip rate.
3. Worn motor parts
Disassemble the air starting motor and inspect the parts.
a. Install a set of new vanes if any vane is cracked or damaged. Also, install a set of new vanes if any vane's
width is 32 mm (1.25 inch) at either end.
b. Replace rotor bearings if any roughness or looseness is apparent in the bearings.
c. Replace the rotor if the body has deep scoring that cannot be removed with the use of emery cloth.
d. Replace the air cylinder if there are any cracks or deep scoring.
e. Clean up end plate scoring with emery cloth that is placed on a flat surface.
4. Air leakage
Check the air starting motor for worn seals. Plug the exhaust. Apply 205 kPa (30 psi) air to the inlet and put the
unit in nonflammable fluid for 30 seconds. If bubbles appear, replace the motor seals.
5. External resistance
Disconnect driven equipment.

Air Starting Motor's Pinion does not Engage with the Flywheel
Probable Cause
1. Broken clutch jaws or other broken parts
Replace the parts, as required.
2. Worn pinion engagement piston
Replace the pinion engagement piston and the seal.

After the Pinion Engages, the Air Starting Motor does not Turn the Flywheel
Probable Cause
1. Broken shafts, gears or clutch jaws
Replace the parts, as required.

Air Starting Motor's Pinion does not Engage Correctly with the Flywheel
Probable Cause
1. Dry pinion shaft
Remove the drive pinion. Put clean grease on the drive shaft splines and the drive pinion.
2. The manual barring group is engaged.
Check the manual barring group and the switches.
3. Fluid in the cylinders
Open the manual valves (Kiene valves) and measure cylinder pressure on each cylinder. If the engine is not equipped with the manual valves, remove the cylinder pressure relief valve or plug. Inspect the cylinders for fluid while the crankshaft is being turned.
4. Improperly installed pinion
Ensure that the pinion is installed for the correct rotation.

CAT SENR3593 - 3612 and 3616 Engines

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