Troubleshooting

G3500H Generator Set Engine

Media Number -M0074324-05 Date Updated -06/01/2020

i05885957

Engine Shutdown Occurs Intermittently

SMCS - 1900-035

Note: Use this procedure only if the engine shuts down completely and the engine must be restarted.

Probable Causes
There is a problem with the input for the keyswitch.

Ignition system

Fuel supply

Recommended Repairs
Table 1
Troubleshooting Test Steps Values Results

Result: An
1. Check for Codes
associated code is
present.
A. Connect Caterpillar Electronic Technician (ET) to the service
tool connector. Refer to Troubleshooting, "Electronic Service
Repair:
Tools", if necessary.
Troubleshoot any
associated codes
B. Download the "Product Status Report" from the engine ECM
before continuing
before performing any troubleshooting or clearing diagnostic
Codes with this test.
trouble codes.
Result: An
C. Determine if the diagnostic trouble code that directed to this
associated code is
procedure is present.
NOT present.
D. Look for active diagnostic codes that are associated with the
Proceed to the next
system for the event code that directed to this procedure.
step.

2. Verify that the Voltage on the Keyswitch Circuit is Stable Keyswitch Result: The input
Input for the keyswitch to
An engine shutdown or an engine overspeed may occur due to a the actuators is
problem with the input for the keyswitch for one of the following: NOT intermittent.

- Actuator for the throttle Proceed to the next

- Actuator for the turbocharger compressor bypass valve step.
- Actuator for the fuel metering valve
- ECM Result: The input
for the keyswitch to
A. Verify that the input for the keyswitch to the actuators is not the actuators is
intermittent. intermittent.

Repair: Remedy the

cause for the
intermittent
keyswitch input.

3. Check the Ignition System

A. Ensure that current parts are used for the following components:

- Transformers
- Extenders
- Spark plugs Result: The Ignition
System is OK.
Inspect the ignition system for the following conditions:
Proceed to the next
1. Check the connection between the ignition transformer and the step.
extender. A loose connection can cause arcing and misfires.
Ignition
Result: A faulty
System
2. Check the connection between the extender and the spark plug component was
for a loose connection or for pin holes that are caused by arcing. identified.
Both conditions can cause misfires.
Repair: Repair or
3. Check the extender for corrosion on the spring. Corrosion may replace the faulty
cause arcing through the extender. component.

4. Check for corrosion on the terminal of the spark plug and check
for wear on the electrode. Both conditions can cause misfires.
Excessive moisture can cause misfire.
Maintain the spark plug according to the engine Operation and
Maintenance Manual.

4. Check the Fuel Supply Fuel Result: A faulty

component was
A. Make sure that fuel is supplied at a sufficient pressure that is identified.
stable. Make sure that the size of the fuel line is sufficient. Inspect
the fuel system for leaks. Repair: Repair or
replace the faulty
The following conditions can cause the engine to malfunction: component.

- Low fuel pressure

- High fuel pressure
- Poor fuel quality

B. Make sure that the fuel pressure is correct. When possible,

interview the operator in order to determine if fuel quality is in
question. Try to determine if the source of the fuel was changed.

Inspect the fuel system components:

- Fuel filter
- Gas pressure regulator
 - Gas shutoff valve
- Fuel metering valve

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