Troubleshooting

G3500H Generator Set Engine

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

i06760271

Engine Overloads
SMCS - 1000-035; 1900-035

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

Table 1
J1939 Code and Description Comments

The engine load has exceeded the trip point and the
92-0
delay time has expired.
Engine Percent Load At Current Speed : High
The engine power is reduced.
- most severe (3)
The code is logged.

The engine load has exceeded the trip point and the
92-15
delay time has expired.
Engine Percent Load At Current Speed : High
The engine power is reduced.
- least severe (1)
The code is logged.

Probable Causes
Engine overload

Cylinder misfire

Low Heating Value (LHV)

Recommended Actions
Table 2
Troubleshooting Test Steps Values Results

Result: The engine is not being overloaded.

1. Check for Engine Overload Proceed to Test Step 2.

Note: When the load that is applied to the
engine is too large, the engine will run in the
lug condition. When the engine is running in
the lug condition, engine rpm does not
increase with an increase of fuel.
Result: The engine is being overloaded.
Load
Repair: Reduce engine load to an acceptable
limit.
If the problem is not resolved, proceed to
Test Step 2.

2. Check for a Cylinder Misfire Misfire Result: There is not a cylinder misfire.
 Note: A cold cylinder will cause the other Proceed to Test Step 3.
cylinders to overload.
Result: There is a cylinder misfire.

Repair: Troubleshoot the cause of the

misfire. Refer to Troubleshooting, "Engine
Misfires, Runs Rough, or Is Unstable" for
additional information.

If the problem is not resolved, proceed to

Test Step 3.

Result: The LHV is NOT OK.

3. Determine the Low Heating Value (LHV)
Repair: Use Cat ET to program the results
for the "Fuel Specific Heat Ratio", "Fuel
A. Obtain a fuel analysis.
Quality", and "Gas Specific Gravity"
parameters. Refer to Systems Operation,
Note: If the quality of the gas is inconsistent,
"Electronic Control System Parameters" for
obtain several analyses over a time.
additional information.
LHV
B. Enter the data into Caterpillar Software,
Program the "Fuel Quality" parameter to the
LERW4485, "Gas Engine Rating Pro
average value of the LHV. Adjust the engine
(GERP)".
operation according to Testing and
Adjusting, "BTU and Precombustion
C. Verify that the exhaust emissions are
Chamber Adjustments".
correct.
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).

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