G3500H Generator Set Engine Caterpillar

Exhaust Temperature - Test

Usage:

Use this procedure to troubleshoot a problem with the exhaust temperature sensors. Also, use this procedure if one of the following diagnostic codes is active or easily repeated.

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Table 1
J1939 Code and Description	Comments
1137-3 Engine Exhaust Gas Port 1 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1137-4 Engine Exhaust Gas Port 1 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1138-3 Engine Exhaust Gas Port 2 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1138-4 Engine Exhaust Gas Port 2 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1139-3 Engine Exhaust Gas Port 3 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1139-4 Engine Exhaust Gas Port 3 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1140-3 Engine Exhaust Gas Port 4 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1140-4 Engine Exhaust Gas Port 4 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1141-3 Engine Exhaust Gas Port 5 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1141-4 Engine Exhaust Gas Port 5 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1142-3 Engine Exhaust Gas Port 6 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1142-4 Engine Exhaust Gas Port 6 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1143-3 Engine Exhaust Gas Port 7 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1143-4 Engine Exhaust Gas Port 7 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1144-3 Engine Exhaust Gas Port 8 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1144-4 Engine Exhaust Gas Port 8 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1145-3 Engine Exhaust Gas Port 9 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is above normal. The code is logged.
1145-4 Engine Exhaust Gas Port 9 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1146-3 Engine Exhaust Gas Port 10 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1146-4 Engine Exhaust Gas Port 10 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1147-3 Engine Exhaust Gas Port 11 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1147-4 Engine Exhaust Gas Port 11 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1148-3 Engine Exhaust Gas Port 12 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1148-4 Engine Exhaust Gas Port 12 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1149-3 Engine Exhaust Gas Port 13 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1149-4 Engine Exhaust Gas Port 13 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1150-3 Engine Exhaust Gas Port 14 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1150-4 Engine Exhaust Gas Port 14 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1151-3 Engine Exhaust Gas Port 15 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1151-4 Engine Exhaust Gas Port 15 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1152-3 Engine Exhaust Gas Port 16 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1152-4 Engine Exhaust Gas Port 16 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1153-3 Engine Exhaust Gas Port 17 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1153-4 Engine Exhaust Gas Port 17 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1154-3 Engine Exhaust Gas Port 18 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1154-4 Engine Exhaust Gas Port 18 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1155-3 Engine Exhaust Gas Port 19 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1155-4 Engine Exhaust Gas Port 19 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1156-3 Engine Exhaust Gas Port 20 Temperature : Voltage Above Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1156-4 Engine Exhaust Gas Port 20 Temperature : Voltage Below Normal	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1180-3 Engine Turbocharger #1 Turbine Inlet Temperature : Voltage Above Normal⁽¹⁾	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1180-4 Engine Turbocharger #1 Turbine Inlet Temperature : Voltage Below Normal⁽¹⁾	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1181-3 Engine Turbocharger #2 Turbine Inlet Temperature : Voltage Above Normal⁽²⁾	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1181-4 Engine Turbocharger #2 Turbine Inlet Temperature : Voltage Below Normal⁽²⁾	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1184-3 Engine Turbocharger #1 Turbine Outlet Temperature : Voltage Above Normal⁽¹⁾	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1184-4 Engine Turbocharger #1 Turbine Outlet Temperature : Voltage Below Normal⁽¹⁾	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1185-3 Engine Turbocharger #2 Turbine Outlet Temperature : Voltage Above Normal⁽²⁾	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.
1185-4 Engine Turbocharger #2 Turbine Outlet Temperature : Voltage Below Normal⁽²⁾	The ISM has detected a voltage in the circuit for the exhaust temperature sensor that is below normal. The code is logged.

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⁽¹⁾	Turbocharger 1 is the right side turbocharger.
⁽²⁾	Turbocharger 2 is the left side turbocharger.

Background Information

The Integrated Sensing Module (ISM) monitors type K thermocouples at each cylinder exhaust port and at the inlets and outlets for both turbochargers. The ISM can also calculate the average temperature for all cylinders. Temperature readings of the thermocouples are available over the CAN data link for use by the Electronic Control Module (ECM) and by other modules. The temperatures can be viewed on Cat^® Electronic Technician (ET).

The ISM generates an event code for each of the following programmable conditions:

High exhaust temperature
High deviation of an exhaust port temperature
Low deviation of an exhaust port temperature
High inlet temperature to the turbocharger turbine
High outlet temperature from the turbocharger turbine

A diagnostic code is generated by the ISM for the circuit of any thermocouple that is shorted to the +Battery side, shorted to ground, or open.

Logged diagnostic codes provide a historical record. Before you begin this procedure, use Cat ET to print the logged codes to a file.

This troubleshooting procedure may generate additional diagnostic codes. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved.

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Illustration 1	g03743379
For the complete circuit details, refer to the full schematic.

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Illustration 2	g03744214
For the complete circuit details, refer to the full schematic.

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Illustration 3	g03744217
For the complete circuit details, refer to the full schematic.

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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. Determine if a code is active or logged.	Codes	Result: A -3 code is active. Proceed to Test Step 2. Result: A -4 code is active. Proceed to Test Step 3. Result: For a code that is logged, but not currently active. Proceed to Test Step 4.
2. Create a Short at the Sensor Connector A. Turn the main disconnect switch to the OFF position. B. Disconnect the sensor with the active -3 code. C. Install the jumper wire between the following terminals at the sensor connector: - Terminal 1 (sensor signal) and Terminal 2 (sensor return) D. Connect Cat ET. E. Use Cat ET to monitor the following: - -4 code F. Turn the main disconnect switch to the OFF position.	Create a Short	Result: The -3 code remains active. Repair: There is an open in the wiring harness. Repair or replace the wiring harness. Verify that the repair eliminated the problem. Result: A -4 code became active. Repair: The wiring harness is OK. Replace the sensor. Verify that the repair eliminated the problem.
3. Create an Open at the Sensor Connector A. Turn the main disconnect switch to the OFF position. B. Disconnect the sensor with the active -4 code. C. Connect Cat ET. D. Use Cat ET to monitor the following: - -3 code E. Turn the main disconnect switch to the OFF position.	Create an Open	Result: The -4 code remains active. Repair: There is an open in the wiring harness. Repair or replace the wiring harness. Verify that the repair eliminated the problem. Result: A -3 code became active. Repair: The wiring harness is OK. Replace the sensor. Verify that the repair eliminated the problem.
4. Perform the Wiggle Test Carefully following this procedure is the best way to identify the root cause of an intermittent problem. A. Connect Cat ET. B. Use CAT ET to perform the following test: - "Wiggle Test" C. Slowly wiggle the wiring and the connectors between the P2 connector and the sensor. Slowly wiggle the wiring and the connectors between the P1 connector and the sensor. Pay particular attention to the wiring near each connector. Be sure to wiggle all the wiring. D. As you wiggle the wiring look for the following problems: - Loose connectors or damaged connectors - Moisture on the connectors or the wiring - Damage that is caused by excessive heat - Damage that is caused by chafing - Improper routing of wiring - Damaged insulation	Test	Result: The wiring failed the Wiggle Test. Repair: There is a problem with the wiring harness. Repair or replace the wiring harness. Verify that the repair eliminated the problem. Result: The wiring passed the Wiggle Test. Repair: The problem may be intermittent. Inspect the wiring harness. Refer to Troubleshooting, "Electrical Connectors - Inspect" for additional information. If the wiring looks OK, perform the following procedure. 1. Turn the main disconnect switch to the OFF position. 2. Disconnect the connectors. Carefully inspect the terminals for proper installation. Make sure that each terminal is clean and dry. 3. Insert a pin into each socket. Verify that each socket grips the pin firmly. Repair any problems. 4. Connect all connectors. 5. 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).