Troubleshooting

G3500H Generator Set Engine

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

i06781656

Engine Overspeeds
SMCS - 1915-035

Use this procedure to troubleshoot an engine overspeed or use this procedure if any of the following event
codes are active or logged.

Table 1
J1939 Code and Comments
Description
The engine rpm has exceeded the trip point that is programmed into the
Electronic Control Module (ECM).
190–0
The shutdown output is activated. The gas shutoff valve is de-energized.
Engine Speed : High -
the ignition is shut off.
most severe (3)
The code is logged.
The engine is shutdown.
The engine rpm has exceeded the trip point that is programmed into the
Electronic Control Module (ECM).
190–15
The shutdown output is activated. The gas shutoff valve is de-energized.
Engine Speed : High -
the ignition is shut off.
least severe (1)
The code is logged.
The engine is shutdown.

Note: Refer to Troubleshooting, "Engine Monitoring System" for information on trip points and delay
times.

The ignition is immediately terminated when the emergency stop button is pressed. Unburned gas remains
in the air inlet and exhaust system.

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.

Probable Causes
Low trip point for engine overspeed

There is a problem with the input for the keyswitch.

Energy of the driven equipment

 Binding of the throttle actuator

Slow governor response

Table 2
Troubleshooting Test Steps Values Results

Result: An associated
code is active.
1. Check for Codes
Repair: Troubleshoot
any associated codes
A. Connect Cat® Electronic Technician (ET) to the service tool before continuing with
connector. Codes this test.
B. Look for active codes that are associated with the system for Result: An associated
the event code. code is NOT present.

Proceed to Test Step 2.

Result: The
programmed trip point
2. Check the Trip Point
for overspeed is correct.
NOTE: Do not program the trip point for engine overspeed
Proceed to Test Step 3.
higher than the maximum ratings of the driven equipment.
Result: The
A. Verify that the trip point for the engine overspeed is properly Trip Point
programmed trip point
programmed. Typically, this parameter is set at 118 percent of
for overspeed is too
rated speed.
high.
B. This parameter requires a factory password to change the trip
Repair: Decrease the
point. Change the trip point to an acceptable speed, if necessary.
programmed trip point
for overspeed.

Result: The input for the

3. Verify that the Voltage on the Keyswitch Circuit is Stable
keyswitch to the
actuators is NOT
An engine shutdown or an engine overspeed may occur due to a
intermittent.
problem with the input for the keyswitch for one of the
following:
Proceed to Test Step 4.
Keyswitch
- Actuator for the throttle
Input Result: The input for the
- Actuator for the turbocharger compressor bypass valve
keyswitch to the
- Actuator for the fuel metering valve
actuators is intermittent.
- ECM
Repair: Remedy the
A. Verify that the input for the keyswitch to the actuators is not
cause for the intermittent
intermittent.
keyswitch input.

4. Check the Driven Equipment Energy Result: No additional

 energy input was
A. Determine if the driven equipment has additional inputs of identified.
energy that could drive the engine beyond the trip point.
Proceed to Test Step 5.

Result:Additional
energy input was
identified.

Repair: Make
corrections to the
installation to prevent
the overspeed from
recurring.

Result: The actuator is

5. Check for Binding of the Throttle Actuator
OK.
A. Set the engine control to the OFF/RESET mode.
Proceed to Test Step 6.
B. Remove the electrical power from the engine. Binding
Result: The 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
Repair: Remedy the
binding. Make the necessary repairs.
cause of the binding.

6. Check for Slow Governor Response

Result: Adjustment is
A. Observe the "Speed Governor Adjustment" screen on the required for the
Caterpillar Electronic Technician (ET). Look for the engine Governor electronic governor.
response to the worst cases for step-loading and unloading. Response
Repair: Adjust the
Refer to System Operation Test and Adjust, "Engine Governing electronic governor.
- Adjust"

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).

Copyright 1993 - 2020 Caterpillar Inc. Wed Jul 01 2020 16:16:17 GMT-0300 (Horário Padrão de Brasília)
All Rights Reserved.
Private Network For SIS Licensees.