G3500H Generator Set Engine Caterpillar

Inlet Air Is Restricted

Usage:

Use this procedure to troubleshoot a high differential pressure for the air inlet system. 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
107-15 Engine Air Filter 1 Differential Pressure : High - least severe (1)	The air filter differential pressure is above the trip point pressure for the delay time. The engine power may be derated. The code is logged.
2809-15 Engine Air Filter 2 Differential Pressure : High - least severe (1)	The air filter differential pressure is above the trip point pressure for the delay time. The engine power may be derated. The code is logged.

Probable Causes

Codes
Air filter element
Enclosure
Sensor
Connectors and wiring

Recommended Actions

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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 code is active or logged. Proceed to Test Step 2.
2. Check for Damaged or Plugged Air Filter Elements Note: For optimum operation, replace the air filter elements when the inlet air restriction reaches 2.5 kPa (10 inch of H₂O). The maximum allowable inlet air restriction is 3.75 kPa (15 inch of H₂O).	Air Filter Element	Result: The air filter element is not plugged and the piping is not restricted. Proceed to Test Step 3. Result: The air filter element is plugged or the piping is restricted. Repair: Clean or replace the air filter element. If problem is not resolved, proceed to Test Step 3.
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 code is active or logged. Proceed to Test Step 2.
2. Check for Damaged or Plugged Air Filter Elements Note: For optimum operation, replace the air filter elements when the inlet air restriction reaches 2.5 kPa (10 inch of H₂O). The maximum allowable inlet air restriction is 3.75 kPa (15 inch of H₂O).	Air Filter Element	Result: The air filter element is not plugged and the piping is not restricted. Proceed to Test Step 3. Result: The air filter element is plugged or the piping is restricted. Repair: Clean or replace the air filter element. If problem is not resolved, proceed to Test Step 3.
3. Check the Enclosure A. Check that the engine has been installed in an enclosure that is sufficiently ventilated.	Enclosure	Result: The engine enclosure is sufficiently ventilated. Proceed to Test Step 4. Result: The engine enclosure is not sufficiently ventilated. Repair: Repair the ventilation for the enclosure. If problem is not resolved, proceed to Test Step 4.
3. Check the Enclosure A. Check that the engine has been installed in an enclosure that is sufficiently ventilated.	Enclosure	Result: The engine enclosure is sufficiently ventilated. Proceed to Test Step 4. Result: The engine enclosure is not sufficiently ventilated. Repair: Repair the ventilation for the enclosure. If problem is not resolved, proceed to Test Step 4.
4. Check the Inlet Restriction Pressure Sensor A. Connect Cat ET. B. Use Cat ET to monitor the following parameters when the engine is off: - Air filter differential pressure - Barometric pressure sensor Note: The air filter differential pressure sensor references the barometric pressure sensor to determine the level of air filter restriction. Verify the accuracy of each sensor compared to local barometric conditions.	Sensor	Result: The inlet restriction pressure sensor and barometric pressure sensor are within .2 PSI of each other. The sensors are reading accurate barometric pressure levels. Proceed to Test Step 5. Result: The inlet restriction pressure sensor or barometric pressure sensor is not OK. Repair: Replace the sensor that is measuring incorrect barometric pressure. If problem is not resolved, proceed to Test Step 5.
5. Inspect the Electrical Connectors and the Wiring A. Turn the main disconnect switch to the OFF position. B. Thoroughly inspect the connectors. Refer to Troubleshooting, "Electrical Connectors-Inspect" for additional information. C. Perform a 45 N (10 lb) pull test on the connector wires. D. Check the harness for abrasions and pinch points.	Connectors and Wiring	Result: There is a problem with the connectors and/or wiring. Repair: Repair or replace the connectors or wiring. Ensure that all the seals are properly in place and ensure that the connectors are coupled. 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).