06/12/2017 G3516B Generator Set ZBC00001-UP(SEBP3863 - 36) - Documentation

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Product: GENERATOR SET
Model: G3516B GENERATOR SET ZBC
Configuration: G3516B Generator Set ZBC00001-UP

Troubleshooting
G3516B Engines
Media Number -RENR2270-09 Publication Date -01/09/2012 Date Updated -19/02/2016

i02113112

Engine Misfires, Runs Rough or Is Unstable

SMCS - 1000-035

Probable Causes
Cold cylinder

Electrical connectors or power supply

Ignition system

Incorrect base timing

Fuel supply

Incorrect air/fuel ratio

Incorrect governor adjustment

Air inlet restriction

Exhaust restriction

Incorrect valve lash

Cylinder head and related components

Throttle

Recommended Repairs
Note: If the symptom only occurs under certain operating conditions (high idle, full load, engine operating
temperature, etc), test the engine under the conditions. Troubleshooting the symptom under other conditions
can give misleading results.

The Caterpillar Electronic Technician (ET) and the Integrated Temperature Sensing Module (ITSM) can be
used to detect a misfiring cylinder. Use the following procedure:

1. Use the "Data Link/Select ECM" option on the Cat ET to select the ITSM.

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06/12/2017 G3516B Generator Set ZBC00001-UP(SEBP3863 - 36) - Documentation

2. Select "Diagnostics/Diagnostic Tests".

3. Select the suspect cylinder and click the "Start" button in the lower left corner of the screen.

Cat ET will display a graph of the cylinder's exhaust gas temperature. The output voltage of the
transformer's secondary circuit, the engine speed, and the desired engine speed are also displayed.

Cold Cylinder
Locate the misfiring cylinder. Check the following components for failure: spark plug, extender, ignition
transformer and primary wiring. Inspect the extender for signs of pin holes and/or arcing.

Refer to Troubleshooting, "Ignition Transformers Secondary Circuit and Spark Plugs".

Electrical Connectors or Power Supply

There may be an intermittent interruption of power. Check the wiring harnesses and the connectors. Inspect
the connectors in the terminal box. Inspect the battery connections and the ground.

Inspect the wiring from the battery to the control modules. Refer to Troubleshooting, "Electrical Power
Supply".

Ignition System
Inspect the ignition transformers for loose connections, for moisture, for short circuits, and for open circuits.
Inspect the primary wiring and the secondary electrical connections.

Make sure that the correct transformers and spark plugs are installed. Inspect the extenders for signs or pin
holes and arcing.

Maintain the spark plug according to the engine's Operation and Maintenance Manual.

Check the Base Timing

Verify that the base timing is correct. Refer to Systems Operation/Testing and Adjusting, "Ignition Timing -
Adjust".

Fuel Supply

Make sure that fuel is supplied at a sufficient pressure that is stable. Make sure that the size of the fuel line is
sufficient. Inspect the fuel system for leaks.

The following conditions can cause the engine to malfunction:

Low fuel pressure

High fuel pressure

Poor fuel quality

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 and fuel metering
valve. Verify that the system's components are operating correctly.

Replace the fuel filter, if necessary.

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Air/Fuel Ratio

An air/fuel mixture that is too rich or too lean will have an adverse effect on engine operation. Verify that the
exhaust emissions are correct. Refer to Systems Operation/Testing and Adjusting, "Air/Fuel Ratio Control -
Adjust".

A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis.

The fuel supply pressure must be adequate and stable.

Governor Adjustment

The governor's parameters must be programmed with the values that provide stable operation. Refer to
Systems Operation/Testing and Adjusting, "Engine Governing - Adjust".

Air Inlet Restriction

The maximum allowable air inlet restriction is 3.75 kPa (15 inches of H2O). If the indication is higher than
the maximum permissible restriction, clean the filter element or install a new filter element. Check the
restriction again. If the restriction remains too high, inspect the air inlet piping for obstructions.

For more information, refer to Systems Operation/Testing and Adjusting, "Restriction of Air Inlet and
Exhaust".

Exhaust Restriction

Check for restriction in the exhaust system. Refer to Systems Operation/Testing and adjusting, "Restriction
of Air Inlet and Exhaust".

Incorrect Valve Lash

Check the valve lash. Refer to Systems Operation, Testing And Adjusting, "Valve Lash and Valve Bridge
Adjustment".

Cylinder Head and Related Components

Measure the cylinder compression. Refer to the engine's Operation and Maintenance Manual, "Cylinder
Pressure - Measure/Record".

Inspect the components of the valve train for good condition. Check for signs of damage and/or wear to the
valves, cylinder head gasket, etc. Inspect the condition of the camshafts. If a camshaft is replaced, new valve
lifters must be installed.

Throttle
Make sure that the throttle actuator is operating properly. If the motion of the actuator is sticky and/or rough,
service the actuator.

For electrohydraulic actuators, make sure that the hydraulic oil is not contaminated.

Copyright 1993 - 2017 Caterpillar Inc. Wed Dec 06 2017 13:57:40 GMT-0200 (Horário brasileiro de verão)
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