Troubleshooting

G3500H Generator Set Engine

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

i07946544

Engine Misfires, Runs Rough or Is Unstable

SMCS - 1000-035

Probable Causes
Excessive load

Incorrect base timing

Fuel supply

Ignition system

Incorrect air/fuel ratio

Incorrect governor adjustment

Binding of the throttle actuator

Incorrect valve lash

Cylinder head and related components

Recommended Repairs
Table 1
Troubleshooting Test Steps Values Results

Result: An
associated code
1. Check for Codes is present.

A. Connect Caterpillar Electronic Technician (ET) to the service tool Repair:

connector. Refer to Troubleshooting, "Electronic Service Tools", if Troubleshoot
necessary. any associated
codes before
B. Download the "Product Status Report" from the engine ECM before continuing
performing any troubleshooting or clearing diagnostic trouble codes. Codes with this test.

C. Determine if the diagnostic trouble code that directed to this Result: An

procedure is present. associated code
is NOT
D. Look for active diagnostic codes that are associated with the system present.
for the event code that directed to this procedure.
Proceed to the
next step.
2. Check for Excessive Load Excessive Result: No
Load excessive load
A. Ensure that the load is not excessive. If necessary, disengage the on the engine.
driven equipment and test the engine.
Proceed to the
next step.

Result: The
engine has an
excessive load.

Repair:
Remedy the
cause of the
excessive load.

Result: The
Base Timing is
correct.

Proceed to the
next step.
3. Check the Base Timing
Base
A. Verify that the base timing is correct. Refer to Systems Timing
Result: The
Operation/Testing and Adjusting, "Ignition Timing - Adjust"
Base Timing is
NOT correct.

Repair:
Correct the
Base Timing.

4. Check the Fuel Supply Fuel Result: The

fuel supply is
A. Make sure that fuel is supplied at a sufficient pressure that is stable. OK.
Make sure that the size of the fuel line is sufficient. Inspect the fuel
system for leaks. Proceed to the
next step.
The following conditions can cause the engine to malfunction:
Result: A
- Low fuel pressure faulty
- High fuel pressure component was
- Poor fuel quality identified.

B. Make sure that the fuel pressure is correct. When possible, interview Repair: Repair
the operator to determine if fuel quality is in question. Try to determine or replace the
if the source of the fuel was changed. faulty
component.
Inspect the fuel system components:

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

5. Check the Ignition System

Result: The
A. Ensure that current parts are used for the following components:
Ignition
System is OK.
- Transformers
- Extenders
Proceed to the
- Spark plugs
next step.
Inspect the ignition system for the following conditions:
Result: A
faulty
1. Check the connection between the ignition transformer and the
component was
extender. A loose connection can cause arcing and misfires.
identified.
2. Check the connection between the extender and the spark plug for a
Ignition Repair: Repair
loose connection or for pin holes that are caused by arcing. Both
System or replace the
conditions can cause misfires.
faulty
component.
3. Check the extender for corrosion on the spring. Corrosion may cause
arcing through the extender.
Result: Worn
spark plug
4. Check for corrosion on the terminal of the spark plug and check for
wear on the electrode. Both conditions can cause misfires.
Repair: If
Excessive moisture can cause misfire.
secondary
Maintain the spark plug according to the engine Operation and
voltage on any
Maintenance Manual.
cylinder is at or
above 100%
5. Check the ignition system components visually.
change spark
Swap coil with adjacent cylinder, start engine, and return to load point
plug.
where initial failure occurred. If failure follows the coil replace the coil,
if the failure stays with the original cylinder replace the spark plug.

Result: The
Air/Fuel Ratio
is correct.

Proceed to the
next step.
6. Check the Air/Fuel Ratio
Air/Fuel
Result: The
A. Verify that the exhaust emissions are correct. Refer to Systems Ratio
Air/Fuel Ratio
Operation/Testing and Adjusting, "Air/Fuel Ratio Control - Adjust".
is NOT
correct.

Repair:
Correct the
Air/Fuel Ratio.

7. Check the Governor Adjustment Governor Result: The

Adjustment Governor
A. The governor parameters must be programmed with the values that Adjustment is
provide stable operation. Refer to Systems Operation/Testing and correct.
Adjusting, "Engine Governing - Adjust".
Proceed to the
next step.

Result: The
Governor
Adjustment is
NOT correct.

Repair:
Correct the
Governor
Adjustment.

Result: The
actuator is OK.
8. Check for Binding of the Throttle Actuator
Proceed to the
next step.
A. Set the engine control to the OFF/RESET mode.
Result: The
B. Remove the electrical power from the engine. Binding
actuator is
NOT OK.
C. Move the throttle plate while you feel the motion. If the motion is
sticky and/or rough, investigate the cause of the binding. Make the
Repair:
necessary repairs.
Remedy the
cause of the
binding.

Result: The
actuator is OK.
9. Check for Binding of the Wastegate
Proceed to the
next step.
A. Set the engine control to the OFF/RESET mode.
Result: The
B. Remove the electrical power from the engine. Binding
actuator is
NOT OK.
C. Move the wastegate while you feel the motion. If the motion is sticky
and/or rough, investigate the cause of the binding. Make the necessary
Repair:
repairs.
Remedy the
cause of the
binding.

10. Check for Binding of the Turbocharger Compressor Bypass Binding Result: The
Valve actuator is OK.

A. Set the engine control to the OFF/RESET mode. Proceed to the

next step.
B. Remove the electrical power from the engine.
Result: The
C. Move the bypass valve while you feel the motion. If the motion is actuator is
 sticky and/or rough, investigate the cause of the binding. Make the NOT OK.
necessary repairs.
Repair:
Remedy the
cause of the
binding.

Result: The
lash is OK.

Proceed to the
11. Check for Incorrect Valve Lash next step.
Lash
A. Check the valve lash. Refer to Systems Operation, Testing and Result: The
Adjusting, "Valve Lash and Valve Bridge Adjustment". lash is NOT
OK.

Repair: Adjust
the lash.

12. Check the Cylinder Head and Related Components Result: A

faulty
A. Measure the cylinder compression. Refer to the engine Operation and component was
Maintenance Manual, "Cylinder Pressure - Measure/Record". identified.
Component
B.Inspect the components of the valve train for good condition. Check Repair: Repair
for signs of damage and/or of wear to the valves, cylinder head gasket, or replace the
and related components. Inspect the condition of the camshafts. If a faulty
camshaft is replaced, new valve lifters must be installed. component.

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