G3500H Generator Set Engine Caterpillar

Engine Shutdown Occurrence

Usage:

Use this procedure to troubleshoot an unexpected engine shutdown. Also, use this procedure if one of the following event codes is active or logged.

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Table 1
J1939 Code and Description	Comments
1109–31 Engine Protection System Approaching Shutdown	The engine protection system is warning of an impending shutdown of the engine. The code is logged
1110–31 Engine Protection System has Shutdown Engine	The engine protection system has shutdown the engine. The "Engine Protection Override Switch" can be activated to resume operation. The code is logged
3607-2 Engine Emergency Shutdown Indication : Erratic, Intermittent, or Incorrect	There are two switch inputs to the Electronic Control Module (ECM) from the E-stop switch. The code will be set if both inputs are not grounded simultaneously or not open circuit simultaneously. The code is logged.
3607-31 Engine Emergency Shutdown Indication	An "Emergency Stop" button is pressed. The shutdown output is activated. The ECM ) de-energizes the gas shutoff valve. The ECM terminates the ignition. The code is logged.
5272-31 Unexpected Engine Shutdown	The engine is in the run mode and the engine speed drops below 100 rpm. The code is logged

Probable Causes

Codes
Operator
Fuel system
Mechanical failure
Switches

Gaseous fuel is present. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Contact your local gas provider immediately for assistance in the event of a leak.

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Unburned gas in the air inlet and exhaust system may ignite when the engine is started. Personal injury and/or property damage may result.

Before starting an engine that may contain unburned gas, purge the unburned gas from the air inlet and exhaust system. Refer to the topic on purging unburned gas in the "Starting the Engine" section.

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Table 2
Troubleshooting Test Steps	Values	Results
1. Check for Codes A. Connect Cat^® Electronic Technician (ET) to the service tool connector. B. Look for active codes that are associated with the system for the event code.	Codes	Result: An associated code is active. Repair: Troubleshoot any associated codes before continuing with this test. Result: A 3607-31 code is active or logged. Proceed to Test Step 5. Result: A 3607-2 code is active or logged. Proceed to Test Step 6. Result: A 5272-31 code is active or logged. Proceed to Test Step 2.
2. Interview the Operator A. Interview the operator and determine the reason for the shutdown.	Operator	Result: The shutdown was not intentional. Proceed to Test Step 3. Result: The shutdown was intentional. Repair: Ensure that the reason for the shutdown has been corrected. Reset the control system. Resume normal operation. If the problem is not resolved, proceed to Test Step 3.
3. Check the Fuel System A. Obtain a fuel analysis. Note: If the quality of the gas is inconsistent, obtain several analyses over a time. B. Enter the data into Caterpillar Software, LERW4485, "Gas Engine Rating Pro (GERP)". C. Verify that the fuel supply pressure is adequate and stable. D. Verify that the size of the fuel line is sufficient. E. Inspect the fuel system for leaks. Note: Always use a gas detector to determine the presence of gaseous fuel. Contact your local provider of gas immediately for assistance. F. Inspect the following fuel system components: - Fuel filter - Gas pressure regulator - Gas shutoff valve - Gas shutoff valve solenoid	Fuel System	Result: The fuel system is OK. Proceed to Test Step 4. Result: The fuel system is NOT OK. Repair: Repair or replace damaged fuel system components. Use Cat ET to program the results for the "Fuel Specific Heat Ratio", "Fuel Quality", and "Gas Specific Gravity" parameters. Refer to Systems Operation, "Electronic Control System Parameters" for additional information. Program the "Fuel Quality" parameter to the average value of the LHV. Adjust the engine operation according to Testing and Adjusting, "BTU and Precombustion Chamber Adjustments". If the problem is not resolved, proceed to Test Step 4.
4. Check for Mechanical Failure	Mechanical Failure	Result: A mechanical failure has not occurred. Proceed to Test Step 5. Result: A mechanical failure has occurred. Repair: Repair or replace damaged components. If the problem is not resolved, proceed to Test Step 5.
5. Verify that an Emergency Shutdown Switch was Activated A. Interview the operator and determine the reason for the emergency stop shutdown.	Switch	Result: The emergency shutdown was not intentional. Proceed to Test Step 6. Result: The emergency shutdown was intentional. Repair: Ensure that the reason for the emergency shutdown has been corrected. Reset the control system. Resume normal operation. If the problem is not resolved, proceed to Test Step 6.
6. Inspect the Emergency Shutdown Switches A. Look for the following signs of damage: - Corrosion - Moisture - Vibration B. Inspect the connectors and the wiring. Note: If both inputs are not grounded simultaneously or not open circuit simultaneously, a code will log.	Switches	Result: There is a problem with the emergency stop switches, connectors and/or wiring. Repair: Repair or replace damaged switch, connectors, or wiring. Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).