Troubleshooting

G3500H Generator Set Engine

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

i07225792

Coolant Temperature Is High

SMCS - 1395-035

Use this procedure to troubleshoot a high coolant temperature. Also, use this procedure if one of the
following event codes is active or logged.

Table 1
J1939 Code and Description Comments

The engine coolant temperature is above the trip point temperature

110-0
for the programmed delay time.
Engine Coolant Temperature :
The engine is shutdown.
High - most severe (3)
The code is logged.

110-15 The engine coolant temperature is above the trip point temperature
Engine Coolant Temperature : for the programmed delay time.
High - least severe (1) The code is logged.

Probable Causes
Codes

Coolant level

Leaks

Heat exchanger

Sensor

Connectors and wiring

Relief valve

Temperature regulators

Water pump

Exhaust restriction

Engine overload

Air/Fuel ratio

Recommended Actions

Steam or hot coolant can cause severe burns

 Steam or hot coolant can cause severe burns.

Do not loosen the filler cap or the pressure cap on a hot engine.

Allow the engine to cool before removing the filler cap or the pressure
cap.

Table 2
Troubleshooting Test Steps Values Results

1. Check for Codes Result: An associated code is active.

Repair: Troubleshoot any associated

A. Connect Cat® Electronic Technician (ET) codes before continuing with this test.
to the service tool connector. Codes
Result: A code is active or logged.
B. Look for active codes that are associated
with the system for the event code. Proceed to Test Step 2.

Result: The coolant level is OK.

Proceed to Test Step 3.

Result: The coolant level is NOT OK.

Coolant
2. Check the Coolant Level
Level
Repair: Add coolant. Determine the cause
of the low coolant level.

If the problem is not resolved, proceed to

Test Step 3.

Result: No presence of bubbles and the

cylinder liners are OK.

Proceed to Test Step 4.

3. Check the Cooling System for Leaks
Result: There is leakage and/or the
Leaks cylinder liners are damaged.
A. Inspect the coolant for presence of
bubbles.
Repair: Repair any leaks. Replace any
damaged cylinder liners.

If the problem is not resolved, proceed to

Test Step 4.

4. Check the Heat Exchanger for Heat Result: The heat exchanger is OK.
Problems Exchanger
Proceed to Test Step 5.
A. Check the cooling fins on the heat
exchanger for dirt and for debris. Result: A problem with the heat
 exchanger has been discovered.
B. Check for sufficient flow and temperature
of the cooling water through the heat Repair: If the temperature of the cooling
exchanger. water is too high, determine the cause.
Clean the components or replace the heat
C. Ensure that the size of the heat exchanger exchanger.
is sufficient.
If the problem is not resolved, proceed to
Test Step 5.

5. Check the Coolant Temperature Sensor

Note: The sensor may be indicating an

incorrect temperature that is within the
normal range of the sensor.

A. Connect Cat ET.

Result: The temperature sensor is OK.
B. Use Cat ET to monitor the following
Proceed to Test Step 7.
temperature:
Sensor Result: The temperature sensor is NOT
- Coolant temperature
OK.
Note: The temperature should rise steadily
If the problem is not resolved, proceed to
as the engine is warmed.
Test Step 6.
C. Ensure that the temperature is reasonable.

D. Reference the reading to another

temperature indicator when possible. Refer
to Testing and Adjusting, "Cooling System"
for additional information.

Result: The connectors and wiring appear

to be OK.
6. Inspect the Electrical Connectors and
the Wiring
Repair: Replace the sensor.
A. Turn the main disconnect switch to the
If the problem is not resolved, proceed to
OFF position.
Test Step 7.
B. Thoroughly inspect the connectors. Refer
Connectors Result: There is a problem with the
to Troubleshooting, "Electrical Connectors-
and Wiring connectors and/or wiring.
Inspect" for additional information.
Repair: Repair or replace the connectors
C. Perform a 45 N (10 lb) pull test on the
or wiring. Ensure that all the seals are
connector wires.
properly in place and ensure that the
connectors are coupled.
D. Check the harness for abrasions and pinch
points.
If the problem is not resolved, proceed to
Test Step 7.
7. Inspect the Pressure Relief Valve Relief Result: The pressure relief valve and the
Valve radiator cap are operating correctly.
A. Pressure-test the cooling system. Refer to
Testing and Adjusting, "Cooling System" for Proceed to Test Step 8.
additional information.
Result: The pressure relief valve or the
B. Check that the seating surfaces of the radiator cap is not operating correctly.
pressure relief valve and the radiator cap are
clean and undamaged. Repair: Clean or replace damaged
pressure relief valve or the radiator cap.

If the problem is not resolved, proceed to

Test Step 8.

8. Check the Water Temperature

Regulators
Result: The temperature regulators are
Note: The water temperature regulators
OK.
should not begin to open until jacket water
reaches opening temperature for the
Proceed to Test Step 9.
regulators.
Result: The temperature regulators are
A. Allow the engine to cool and then start
Regulators NOT OK.
the engine. Check the hose at the outlet for
the jacket water. If the hose is warm and
Repair: Replace the water temperature
normal operating temperature is not achieved
regulators.
yet, a regulator may be stuck open.
If the problem is not resolved, proceed to
B. If the water temperature regulators are
Test Step 9.
malfunctioning, check the water temperature
regulators. Refer to Testing and Adjusting,
"Cooling System" for additional information.

Result: The water pump is OK.

9. Inspect the Water Pump Proceed to Test Step 10.

A. Inspect the impeller of the water pump for Result: The water pump is NOT OK.
damage or erosion. Water
Pump Repair: Repair or replace damaged water
B. Ensure that the drive gear is not loose on pump components.
the drive shaft of the water pump.
If the problem is not resolved, proceed to
Test Step 10.

10. Check for a Restriction in the Exhaust Restriction Result: The exhaust restriction
System measurement is OK.

Note: A restriction of the exhaust can cause Proceed to Test Step 11.
high cylinder temperatures.
Result: The exhaust restriction
A. Measure the exhaust restriction during measurement is NOT OK.
 engine operation with a load. For data that is
specific to your engine, refer to the Technical Repair: Repair or replace damaged
Marketing Information (TMI). exhaust system components.

If the problem is not resolved, proceed to

Test Step 11.

Result: The engine is not being

overloaded.
11. Check for Engine Overload
Proceed to Test Step 12.
Note: When the load that is applied to the
Result: The engine is being overloaded.
engine is too large, the engine will run in the Load
lug condition. When the engine is running in
Repair: Reduce engine load to an
the lug condition, engine rpm does not
acceptable limit.
increase with an increase of fuel.
If the problem is not resolved, proceed to
Test Step 12.

12. Check the Air/Fuel Ratio

Result: The air/fuel ratio is NOT OK.
Note: An air/fuel mixture that is too rich will
cause overheating. A change in the fuel Repair: Use Cat ET to program the results
energy content will change the air/fuel ratio. for the "Fuel Specific Heat Ratio", "Fuel
Quality", and "Gas Specific Gravity"
A. Obtain a fuel analysis. parameters. Refer to Systems Operation,
"Electronic Control System Parameters"
Note: If the quality of the gas is inconsistent, for additional information.
Air/Fuel
obtain several analyses over a time.
Ratio
Program the "Fuel Quality" parameter to
B. Enter the data into Caterpillar Software , the average value of the LHV. Adjust the
"Gas Engine Rating Pro (GERP)". engine operation according to Testing and
Adjusting, "BTU and Precombustion
C. Verify that the fuel supply pressure is Chamber Adjustments".
adequate and stable.
Verify that the repair eliminated the
D. Verify that the exhaust emissions are problem.
correct.

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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