3500B Locomotive Engines Caterpillar

• Active Engine Shutdown

• Fuel Supply

• Air Shutoff is closed.

• Electrical power supply

• Electrical connectors

• Engine Speed/Timing sensor

• Personality Module

• Combustion

• Starting Aids

• Prelube

• Fuel Position Multiplier

Perform the following tests in order:

1. Use the Electronic Service Tool to determine if any active shutdowns are present. If a Shutdown is Active, determine the reason. After you correct the problem, turn the keyswitch to the OFF position for at least 15 seconds before you try to restart the engine. Check that the Emergency Shutdown Switch is not active. Refer to Troubleshooting, "Emergency Stop Switch".

2. Visually check fuel level. If necessary, add fuel. If cold ambient conditions exist, check operation of starting aids. Replace the ether canister if the ether is low. Ensure the proper operation of the Jacket Water Heater. Repair the Jacket Water Heater and/or replace the Jacket Water Heater. Check for presence of solidified fuel (wax).

   1. Check the fuel system, if there is no smoke at the exhaust. Check fuel lines for the following problems: restrictions, collapse and pinched line. Repair the lines and/or replace the lines. Refer to the Testing and Adjusting, "Fuel System".

   2. Check the fuel tank for foreign objects which may block the fuel supply. Check for air in the low pressure fuel supply system after you perform the following procedures:
      • Replacing the fuel filters

      • Working on the low pressure fuel supply circuit

      • Replacing unit injectors

   3. Purge air from the low pressure fuel supply circuit with the hand priming pump and by cranking the engine in 30 second cycles. After you crank the engine, stop for two minutes. This will allow the starting motor to cool. Loosen the vent plug for the fuel return line. The plug is located on the rear upper left side of the engine block. Hand prime the engine again if air in fuel continues. A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel.

   4. Check fuel quality. In temperatures below 0 °C (32 °F), check for solidified fuel (wax). Refer to Special Instruction, SEBD0717, "Diesel Fuels And Your Engine". Check the fuel pressure while the engine is cranking. Check the fuel pressure at the filter. Refer to the Specifications manual for correct pressure values. If pressure is low, check for plugged 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. Check for a problem with the combustion system.

3. Check that both of the Air Shutoffs are closed.

4. Refer to Troubleshooting, "Electrical Power Supply".

5. Check for correct installation of the ECM connectors J1/P1, J2/P2, Primary Engine Speed/Timing Sensor J20/P20, Secondary Engine Speed/Timing Sensor J61/P61 and Unit Injector connectors J4/P4 through J19/P19. Refer to Troubleshooting, "Inspecting Electrical Connectors".

6. Crank the engine and observe the engine rpm on the Electronic Service Tool Status screen. If the Electronic Service Tool indicates 0 rpm, refer to troubleshooting, "Engine Speed/Timing Sensor".

7. The diagnostic code 253-02 should not be present. If the diagnostic code is present, refer to Troubleshooting, "Programming Parameters".

8. Check for a combustion problem.

9. If cold or ambient conditions are present, check the operation of the starting aids. Check the heater for the cylinder block for a malfunction.

10. Allow the engine to complete the prelube cycle.

11. Refer to Troubleshooting, "Fuel Position Multiplier".