Troubleshooting

G3500H Generator Set Engine

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

i05193813

Engine Does Not Crank

SMCS - 1000-035; 1450-035

Probable Causes
Engine shutdown switches

Diagnostic codes and event codes

Batteries

Engine starting system

Flywheel ring gear

Driven equipment

Engine accessories

Hydraulic cylinder lock

Internal engine problem

Configuration parameters

Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in the order of the
listed test steps.

Table 1
Troubleshooting Test Steps Values Results

1. Check the Engine Shutdown Switches Shutdown Results: The

Switches shutdown
A. The engine shutdown switches should be in the RUN position. switches are OK.
Ensure that the shutdown switches are in the proper positions. Use
Caterpillar Electronic Technician (ET) to verify the status of the Repair: Proceed
"EMCP" and the "Remote E-Stop Switch" parameters. to the next Step

B. When a shutdown occurs, the Electronic Control Module (ECM) Results: The
must be powered down for at least 15 seconds prior to attempting to shutdown switch
start the engine. is NOT OK.

Repair: Perform
the necessary
repairs.
 If the problem is
not resolved,
proceed to the
next step.

Results: The
batteries are OK.

Repair: Proceed
2. Check the Batteries to the next Step

A. Inspect the batteries. Results: The

batteries are NOT
B. Charge the batteries, if necessary. Refer to Special Instruction, OK.
SEHS7633, "Battery Test Procedure". Batteries
Repair: Perform
C. Load test the batteries. Refer to Special Instruction, SEHS9249, the necessary
"Use of 4C-4911 Battery Load Tester for 6, 8 V and 12 V Lead Acid repairs.
Batteries"
If the problem is
not resolved,
proceed to the
next step.

Results: The
electric starter is
OK.
3. Check the Electric Starting System (if applicable)
Repair: Proceed
A. If the application is equipped with an electric starting system, to Test Step 7
perform the following procedure:
Proceed to Test
a. Check the wiring to the starting motor solenoid. Refer to the Step
electrical schematic.
Results: The
b. Check the engine start switch and the engine start relay for Starter electric starter is
electrical power. NOT OK.

c. Check the starting motor cables. If the starting motor cables are Repair: Perform
corroded, remove the starting motor cables and clean the starting the necessary
motor cables. repairs.

d. Test the operation of the starting motors. If the problem is

not resolved,
proceed to the
next step.

4. Check the Air Starting System (if applicable) Starter Results: The air
starter is OK.
A. If the application is equipped with an air start system, perform the
following procedure: Repair: Proceed
to Test Step 7
a. Verify that the air start system has an adequate supply pressure for
starting. Proceed to Test
Step
b. Check the wiring to the air start relay that is for the air starting
motors. Refer to the applications electrical schematic. Results: The air
starter is NOT
c. Check the engine start switch for electrical power. OK.

d. Check the air start supply lines. If the supply lines are leaking or Repair: Perform
damaged, repair the lines. the necessary
repairs.
e. Test the operation of the air start motors.
If the problem is
not resolved,
proceed to the
next step.

Results: The
5. Check the Hydraulic Starting System (if applicable) hydraulic starter
is OK.
A. If the application is equipped with a hydraulic starting system,
perform the following procedure: Repair: Proceed
to Test Step 7
a. Verify that the hydraulic starting system has an adequate supply
pressure for starting. Results: The
hydraulic starter
b. Check the wiring to the start relay that is for the starting motors. is NOT OK.
Starter
Refer to the applications electrical schematic.
Repair: Perform
c. Check the engine start switch for electrical power. the necessary
repairs.
d. Check the hydraulic starting lines. If the supply lines are leaking or
damaged, repair the lines. If the problem is
not resolved,
e. Test the operation of the hydraulic starting motors. proceed to the
next step.

6. Inspect the Flywheel Ring Gear Ring Gear Results: The

flywheel ring
A. Inspect the flywheel ring gear for damage. gear is OK.

Repair: Proceed
to the next Step.

Results: The
flywheel ring
gear is NOT OK.

Repair: Perform
the necessary
repairs.

If the problem is
not resolved,
 proceed to the
next step.

Result The
engine
accessories are
OK.

Result: Proceed
7. Check the Engine Accessories to the next Step

A. Remove engine accessories that may prevent the engine cranking Result The
and inspect the accessories. engine
Engine
accessories and
accessories
B. The following accessories may prevent the engine cranking: transmission are
not OK.
- Engine oil pump
- High-pressure fuel pump Repair: Perform
the necessary
repairs.
If the problem is
not resolved,
proceed to the
next step.

Result: The
engine does not
have a hydraulic
8. Check for Hydraulic Cylinder Lock cylinder lock.

A. If an injector has been replaced, evacuate any fluids from the Repair: Proceed
cylinder and attempt to start the engine. Fuel will flow from the to the next Step.
cylinder head into the cylinders when a unit injector is removed.
Result: The
B. If the engine will not start, check for fluid in the cylinders Hydraulic engine has a
(hydraulic cylinder lock) by removing the individual unit injectors. cylinder hydraulic cylinder
Check for damaged seals. Determine the type of fluid that locked up lock lock.
the cylinder.
Repair: Perform
C. If there was a coolant leak, determine the cause of the leak. the necessary
repairs.
D. If there was excessive fuel in the cylinder, replace the seals and
reinstall the injector. Drain any excess fuel from the cylinder head. If the problem is
not resolved,
proceed to the
next step.

9. Check for an Internal Engine Problem Mechanical Result: No

problem mechanical
A. If a mechanical problem is suspected, disassemble the engine. problem
Refer to the Disassembly and Assembly manual. Inspect the internal
components for the following conditions: Result: The
 engine has
- Seizure mechanical
- Broken components problems.
- Bent components
Repair: Repair or
replace any worn
parts. Refer to the
Disassembly and
Assembly
manual.

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