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Shutdown SIS

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Product: GAS ENGINE

Model: G3612 GAS ENGINE BKE00808
Configuration: G3612 GENERATOR AND INDUSTRIAL BKE00001-UP

Troubleshooting
G3600 Engines
Media Number -RENR5910-06 Publication Date -01/10/2010 Date Updated -12/10/2010

i05096582

Engine Cranks but Does Not Start

SMCS - 1000-035; 1450-035

Use this procedure if the following event code is active. Refer to Troubleshooting, "Event Codes" for
information about event codes and the default trip points for this code.

Table 1
Event Code
System
Description Conditions which Generate this Code
Response
The engine is cranking and the pressure switch for the
The shutdown
E498(3) Fuel prelube is closed. The Electronic Control Module (ECM)
output is
Pressure Present has energized the Gas Shutoff Valve (GSOV) but the ECM
activated. The
During Initial has not energized the fuel actuator solenoid. The air/fuel
code is logged.
Cranking pressure module detects a differential pressure for fuel to
air of at least 0.5 kPa (0.073 psi).

Probable Causes
• Hydraulic oil pressure switch is open

• Air/Fuel pressure module

• Fuel pressure is present during initial cranking.

• Slow cranking

• Cold engine

• Excessive load

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• Incorrect starting position for the air choke

• Inlet air restriction

• Problem with the air/fuel mixture

• Problem with the gas shutoff valve

• Electrical connectors or power supply

• No signal from the engine speed/timing sensor

• Ignition system

Recommended Actions
Hydraulic Oil Pressure Switch Is Open

The hydraulic oil pressure switch contact must close when the engine starts cranking and the
hydraulic oil pressure rises. To check the switch contact, perform the following procedure:

1. Disconnect the engine harness from the hydraulic oil pressure switch.

2. Connect multimeter leads to the switch outputs "A" and "B".Turn on the continuity function.

3. Crank the engine.

The expected response is continuity between "A" and "B" when the hydraulic oil pressure rises.

If there is no continuity between "A" and "B" while the hydraulic oil pressure rises, replace the
switch.

If the hydraulic oil pressure does not rise, refer to Troubleshooting, "Electrohydraulic System Oil
Pressure Is Low".

Air/Fuel Pressure Module

Perform a calibration procedure on the Air/Fuel pressure module. Refer to Troubleshooting, "Air/Fuel
Pressure Module - Calibrate".

Fuel Pressure is Present During Initial Cranking

If fuel pressure is present before the fuel command, the engine will not start.

If an unexpected shutdown or a fast shutdown occurred, the fuel actuator may have remained open. If
service was performed on the actuator, the actuator may have remained open. Before you crank the
engine again, make sure that the actuator is closed.

Inspect the fuel actuator and the actuator linkage. Inspect the rod ends for damage and/or for wear.
Make sure that the components are fastened securely. Make corrections, if necessary.

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Make sure that the linkage is adjusted according to the engine Specifications, "Fuel Control".

The fuel actuator may be stuck. Make sure that the actuator can move smoothly. Inspect the actuator
according to Operation and Maintenance Manual, "Electrohydraulic Actuator - Inspect". Recondition
the actuator, if necessary.

Slow Cranking

The cranking speed must be sufficient for engine start-up. Inspect the starting system. Make sure that
the air supply has sufficient pressure. If the starting motor is suspect, refer to Troubleshooting, "Air
Starting Motor Problem".

Note: The target minimum cranking speed is 80 rpm.

Cold Engine

If the engine is too cold, the engine may not start. Refer to Application and Installation, LEKQ7249,
"Ambient Considerations".

Excessive Load

Make sure that the load is not excessive. Reduce the load. If necessary, disengage the driven
equipment and test the engine.

Air Choke

The air choke is maintained at a fixed position during start-up. If the air choke is closed too far, there
may be insufficient air for combustion. If the air choke is opened too far, the air/fuel mixture may be
too lean for combustion.

Make sure that the programmable "Engine Start Choke Position" is correct. Refer to Systems
Operation/Testing and Adjusting, "Electronic Control System Parameters".

Inlet Air Restriction

The air filter elements may be plugged. For optimum operation, replace the air filter elements when
the inlet air restriction reaches 2.5 kPa (10 inches of H2O). The maximum allowable inlet air
restriction is 3.75 kPa (15 inches of H2O).

If the inlet air restriction is excessive, determine the cause of the restriction and correct the condition.

Air/Fuel Mixture

The following conditions can cause the engine to malfunction:

• Low fuel pressure

• High fuel pressure

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• Poor fuel quality

• Incorrect air/fuel ratio

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. Inspect the fuel filter, the gas pressure regulator,
the gas shutoff valve, and the gas shutoff valve solenoid.

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.

Check the needle valves for the precombustion chambers. If the needle valves are closed, no fuel is
supplied to the precombustion chamber. If the needle valves are open too far, the air/fuel mixture will
be too rich for combustion.

If the adjustment of the needle valves is suspect, fully close all of the valves. Open the needle valves
for four full turns. Adjust the needle valves according to Systems Operation/Testing and Adjusting,
"BTU and Precombustion Chamber Adjustments".

Check the position of the air choke plate. The orientation of the plate is represented by the groove on
the end of the shaft for the choke plate. The air choke is opened for start-up. If the air choke is closed,
the air/fuel mixture will be too rich for combustion. If the air choke is open too far, the air/fuel
mixture will be too lean. Make sure that the programmable starting position for the air choke is
correct.

During cranking, the fuel actuator begins to open at approximately 50 rpm. The actuator opens for
approximately 5 to 10 percent of the full travel. If the actuator opens for more than 30 percent, the
fuel pressure is probably too low.

Make sure that the actuator and the linkage are operating properly. For information on maintaining the
actuator, refer to the Operation and Maintenance Manual, "Electrohydraulic Actuator - Inspect". For
information on troubleshooting the actuator, refer to Troubleshooting, "Fuel Actuator - Test".

Gas Shutoff Valve

During cranking, measure the pressure in the fuel manifold. The gas pressure must be 1 to 10 kPa
(0.15 to 1.5 psi). If the pressure is zero, the gas shutoff valve may not be operating properly. Refer to
the Operation and Maintenance Manual, "Gas Shutoff Valve - Inspect".

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 Electronic control Module (ECM). Inspect the wires and the
power relay. Check the power and ground connections. Refer to Troubleshooting, "Electrical Power
Supply - Test".

Make sure that the run relay is activated. Refer to Troubleshooting, "Indicator Lamp - Test".

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Engine Speed/Timing Sensor

Make sure that the engine speed/timing sensor and the timing wheel are installed correctly. If the
engine speed/timing sensor is suspect, refer to Troubleshooting, "Speed/Timing - Test".

Ignition System

Under certain conditions, condensation forms on the spark plugs after the engine is shut down. The
condensation can prevent the engine from restarting.

Maintain the spark plug according to Operation and Maintenance Manual, "Ignition System Spark
Plugs - Check - Adjust".

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. For information on
troubleshooting the ignition system, refer to Troubleshooting, "Ignition Primary - Test" and
Troubleshooting, "Ignition Secondary - Test".

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

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