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Product: GENERATOR SET


Model: 3516B GENERATOR SET FDN
Configuration: 3516B Generator Set FDN00001-UP

Troubleshooting
3500B and 3500C Generator Set Engines
Media Number -RENR5059-04 Publication Date -01-08-2007 Date Updated -15-08-2007

i02462365

Event Codes
SMCS - 1901-038

Event codes alert the operator that an abnormal engine operating condition such as low oil pressure or high
coolant temperature has been detected. When the event code is generated, the event is active.

Active Event Codes


An active event code represents a problem with engine operation. Correct the problem as soon as possible.

Active event codes are listed in ascending numerical order. The code with the lowest number is listed first.

Illustration 1 is an example of the operating range of a temperature sensor. Do not use the Illustration to
troubleshoot temperature sensors.

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Illustration 1 g01138880
Example of the typical operating range of a temperature sensor

(1) This area represents the normal operating range of the parameter. The normal output voltage of the sensor is between 0.2
VDC and 4.2 VDC.

(2) In this area, the temperature above 107 C (225 F) is higher than normal. The output voltage of the sensor will generate an
event code. The sensor does not have an electronic problem.

(3) In these areas, the output voltage of the sensor is too high or too low. The voltage is outside of the normal range. The

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electronic problem will generate a diagnostic code. Refer to Troubleshooting, "Troubleshooting with a Diagnostic Code" for
additional information on diagnostic codes.

Events are represented in two formats. In the first format, the "E" means that the code is an event code. The
"XXX" represents a numeric identifier for the event code. This is followed by a description of the code. If a
warning, a derate, or a shutdown is applicable, the numeric identifiers are different. Refer to the following
example:

l E004 Engine Overspeed Shutdown

In the second format, the "E" means that the code is an event code. The "XXX-X" represents a numeric
identifier for the event code. The fourth "X" identifies the event as a warning, a derate, or a shutdown. This
is followed by a description of the code. Refer to the following example:

l E360-1 Low Oil Pressure Warning

l E360-2 Low Oil Pressure Derate

l E360-3 Low Oil Pressure Shutdown

The definition for a warning, a derate, and a shutdown are defined below:

Warning - This condition represents a serious problem with engine operation. However, this condition does
not require a derate or a shutdown.

Derate - For this condition, the ECM reduces the engine's power in order to help prevent possible engine
damage.

Shutdown - For this condition, the ECM shuts down the engine in order to help prevent possible engine
damage.

Logged Event Codes


When the ECM generates an event code the ECM logs the code in permanent memory. The ECM has an
internal diagnostic clock. The ECM will record the following information when an event code is generated:

l The hour of the first occurrence of the code

l The hour of the last occurrence of the code

l The number of occurrences of the code

Logged events are listed in chronological order. The most recent event code is listed first.

This information can be helpful for troubleshooting intermittent problems. Logged codes can also be used to
review the performance of the engine.

Clearing Event Codes


A code is cleared from memory when one of the following conditions occur:

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l The code does not recur for 100 hours.

l A new code is logged and there are already ten codes in memory. In this case, the oldest code is
cleared.

l The service technician manually clears the code.

Always clear logged event codes after investigating and correcting the problem which generated the code.

Troubleshooting
For basic troubleshooting of the engine, perform the following steps in order to diagnose a malfunction:

1. Obtain the following information about the complaint:

The event and the time of the event

Determine the conditions for the event. The conditions will include the engine rpm and the load.

Determine if there are any systems that were installed by the dealer or by the customer that
could cause the event.

Determine whether any additional events occurred.

2. Verify that the complaint is not due to normal engine operation. Verify that the complaint is not due to
error of the operator.

3. Narrow the probable cause. Consider the operator information, the conditions of operation, and the
history of the engine.

4. Perform a visual inspection. Inspect the following items:

Fuel supply

Oil level

Oil supply

Wiring

Connectors

Be sure to check the connectors. This is very important for problems that are intermittent. Refer to
Troubleshooting, "Inspecting Electrical Connectors".

If these steps do not resolve the problem, identify the procedures in this manual that best describe the event.
Check each probable cause according to the tests that are recommended.

Trip Points for the Monitoring System


The monitoring system determines the level of action that is taken by the ECM in response to a condition

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that can damage the engine. When any of these conditions occur, the appropriate event code will trip.

Table 2 contains the conditions that are monitored and the default trip points for each condition. Each
condition has an associated parameter. The settings for each parameter can be viewed with the Caterpillar
Electronic Technician (ET). The trip points for some of the parameters may be adjustable with Cat ET.

Table 1

Default Trip Points for the Monitoring System


Delay Time in
Trip Point
Seconds
Condition Action
Default Default
Min Max Min Max Default
State
E004 Engine Shutdown 1200 rpm 2400 rpm
0 5 0 2124 rpm On
Overspeed

E007 High
60 107 C
Aftercooler Derate 1 5 40 C 107 C (224 On
(224 F)
Temperature (104F) F)

E008 High
Shutdown 60 107 C
Aftercooler 1 5 40 C 107 C (224 On
(224 F)
Temperature (104F) F)

E009 High 4562 kPa


Derate 0 0 0 250 kPa 762 kPa (111 On
Altitude (662 psi)
(36 psi) psi)

E012 High
60 0.5 kPa
Crankcase Derate 1 10 6.0 kPa (1 6.0 kPa (1 On
(0.1 psi)
Pressure psi) psi)

E013 High
Shutdown 60 0.5 kPa
Crankcase 1 3 6.0 kPa (1 3.5 kPa (0.5 On
(0.1 psi)
Pressure psi) psi)

E015 High 30 (no


60 90 C 107 C
Engine Coolant Derate 1 derate) 107 C (225 On
(194 F) (225 F)
Temperature F)

E016 High
Shutdown 60 90 C 107 C
Engine Coolant 1 5 107 C (225 On
(194 F) (225 F)
Temperature F)

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E017 High
Warning 60 90 C 102 C
Engine Coolant 1 5 102 C (216 On
(194 F) (216 F)
Temperature F)

E021 High
60 500 C 800 C
Exhaust Derate 1 5 750 C On
(932 F) (1472 F)
Temperature (1382 F)

E031 Inlet Air 60


Derate 1 5 1 kPa (0.1 7 kPa (1 7 kPa (1 psi) On
Restriction
psi) psi)

E038 Low
Warning 60 63 C 85 C
Engine Coolant 1 5 80 C (176 On
(145 F) (18500
Temperature F)
F)
E040 Low
Shutdown 15 (1) (1) (1)
Engine Oil 1 9 On
Pressure
E043 Low
Warning 30
System Voltage 1 10 20V 22V 20V On

E095 Engine
Warning 60
Fuel Filter 1 5 70 kPa 105 kPa 105 kPa (15 On
Restriction (10 psi) (15 psi) psi)

105 kPa 105 kPa (15


E099 Engine (15 psi) psi)
Warning 60
Oil Filter 1 5 70 kPa On
Restriction (10 psi) 124 kPa
124 kPa (18
(18 psi)
(2) psi) (2)

E100 Low
Warning 15 (1) (1) (1)
Engine Oil 1 4 On
Pressure

E101 High
Warning 60 0.5 kPa
Crankcase 1 3 6 kPa (0.9 2 kPa (0.3 On
(.07 psi)
Pressure psi) psi)

E162 High
Warning
Boost Pressure 0 0 0 300 kPa 600 kPa 400 kPa (58 Off
(43 psi) (87 psi) psi)

E162 High Derate 0 0 0 Off


Boost Pressure 300 kPa 600 kPa 400 kPa (58

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(43 psi) (87 psi) psi)

E173 High
Warning 60 500 C 800 C
Exhaust 1 5 600 C On
(932 F) (1472 F)
Temperature (1112F)

E190 Engine Warning 1200 rpm 2400 rpm


0 0 0 2124 rpm On
Overspeed

E198 Low Fuel Shutdown 20 20


20 320 kPa 320 kPa 320 kPa (46 On
Pressure
(46 psi) (46 psi) psi)
E255
Diagnostic Warning N/A N/A Disabled Enabled
N/A Enabled On
Reset (Active
Only)
Shutdown N/A N/A Inactive
E264 E-Stop N/A Active Inactive On

E272 Inlet Air Warning 60


1 5 3 kPa (0.4 7 kPa (1 7 kPa (1 psi) On
Restriction
psi) psi)

E279 High
Warning 60 102 C
Aftercooler 1 5 40 C 102 C (216 On
(216 F)
Temperature (104F) F)

"E-Stop"is The
E2087 Air active and/or device is
Shutdown N/A N/A
Intake Shutoff N/A N/A N/A the engine not
overspeed is installed.
active.
The
E2088 Air
The The detection is The
Intake Shutoff
device is device is disabled and device is
Detection Warning N/A N/A
N/A not not the air not
Circuit
installed. installed. shutoff installed.
Detected but
switch is
Not Installed
active.
E2143 Low
Warning N/A N/A
Engine Coolant N/A N/A N/A N/A N/A
Level
(1) Map dependent value
(2) This setting only applies to 2.5 mW Tier II generator sets.

Copyright 1993 - 2008 Caterpillar Inc.

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