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Troubleshooting
G3516B Engines
Media Number -RENR2270-09 Publication Date -01/09/2012 Date Updated -19/02/2016

i02187199

Integrated Temperature Sensing Module (ITSM)

SMCS - 1901-038

System Operation Description:

The Integrated Temperature Sensing Module (ITSM) monitors type K thermocouples at each cylinder
exhaust port and at the inlets and outlets for both turbochargers. The ITSM can also calculate the average
temperature for each cylinder bank (left and right). Temperature readings of the thermocouples are
available over the Cat Data Link for use by the Electronic Control Module (ECM) and other modules. The
temperatures can be viewed on the Caterpillar Electronic Technician (ET).

The ITSM generates event codes 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 ITSM for the circuit of any thermocouple that is shorted to the
+Battery side, shorted to ground, or open.

Logged diagnostic codes provide an 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 g01076997
Schematic for the circuit of the ITSM
The ECM is connected to the ITSM via the J1/P1 connectors and the terminal box J5/P5 connectors. The J1/P1 and J5/P5 connectors
are not shown. For the actual wiring, refer to the schematic for the engine electrical system.

Test Step 1. Inspect the Electrical Connectors and Wiring

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Illustration 2 g01075108
Terminal box
(1) ECM connectors J1/P1
(2) 16 amp circuit breaker
(3) J5/P5 connectors for the harness from the ITSM

A. Set the engine control to the OFF/RESET mode. Switch 16 amp circuit breaker (2) to the OFF
position.

Note: For the following steps, refer to Troubleshooting, "Inspecting Electrical Connectors".

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Illustration 3 g01075116
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Front view
(1) J40/P40 connectors for the harness from the thermocouples
(2) J18/P18 connectors for the harness to the terminal box

B. Thoroughly inspect each of the following connectors:

J1/P1 connectors

J5/P5 connectors on the terminal box

J18/P18 and J40/P40 connectors for the ITSM

a. Check the torque of the allen head screw for the ECM connectors. The proper torque is
6 ± 1 N·m (53 ± 9 lb in).

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Illustration 4 g01075122
Harness side of the P1 connector
(P1-8) Cat Data Link +
(P1-9) Cat Data Link −

b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the
ITSM.

c. Thoroughly inspect the J18/P18 and J40/P40 connectors. Carefully inspect the connectors for
each of the thermocouples. Check the harnesses and wiring for abrasion and for pinch points
from each component to the ECM.

Expected Result:

All of the connectors, pins, and sockets are connected properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.

Results:

OK - The components are in good condition with proper connections. Proceed to Test Step 2.

Not OK - The components are not in good condition and/or at least one connection is improper.

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Repair: Perform the necessary repairs and/or replace parts, if necessary. If the wiring harness from
the thermocouples to the ITSM requires repair, replace the harness in order to ensure reliable
operation.

All of the wiring from the thermocouples to the ITSM must be type K. The polarity of the wires from
each thermocouple to the ITSM must be maintained in order for the ITSM to read the correct
temperatures.

STOP

Test Step 2. Check for Diagnostic Codes

A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".

B. Switch the 16 amp circuit breaker ON. Set the engine control to the STOP mode.

C. Access the "Active Diagnostic" screen for the ITSM on Cat ET. Determine if any of the following
diagnostic codes are active:

1042-09 Unable to communicate with ITSM

1489-03 through 1492-03 ("short to +batt")

1489-04 through 1492-04 ("short to ground")

1489-05 through 1492-05 ("open circuit")

1531-03 through 1546-03 ("short to +batt")

1531-04 through 1546-04 ("short to ground")

1531-05 through 1546-05 ("open circuit")

Expected Result:

None of the above codes are active.

Results:

OK - None of the above codes are active.

Repair: If any of the above codes are logged and the engine is not running properly, refer to
Troubleshooting, "Troubleshooting Without a Diagnostic Code".

If the engine is running properly at this time, there may be an intermittent problem in a harness that is
causing the code to be logged. Refer to Troubleshooting, "Inspecting Electrical Connectors".

STOP

Active 1042-09 code - There is a communication problem between the ITSM and the ECM. Proceed
to Test Step 3.

Active "short circuit" diagnostic code - Proceed to Test Step 6.

Active "open circuit" diagnostic code - Proceed to Test Step 7.

Test Step 3. Verify that the ITSM is Receiving Electrical Power

A. Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.

B. Disconnect the P18 connector.

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C. Switch the 16 amp circuit breaker ON. Set the engine control to the STOP mode.

D. Measure the voltage between terminals J18-A and J18-B.

E. Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.

Expected Result:

The voltage measurement is approximately equal to the battery voltage.

Results:

OK - The voltage measurement is approximately equal to the battery voltage. Proceed to Test Step 4.

Not OK - The voltage measurement is not approximately equal to the battery voltage. There is a
problem with a wiring harness or a connector.

Repair: Refer to Troubleshooting, "Electrical Power Supply".

STOP

Test Step 4. Check the Continuity of the Wiring for the Cat Data Link

A. Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.

B. Disconnect the J1/P1 connectors.

C. Check the continuity of the wire between terminals J1-8 and J18-J.

D. Check the continuity of the wire between terminals J1-9 and J18-N.

Expected Result:

The continuity of the wiring between the terminals is good.

Results:

OK - The continuity of the wiring between the terminals is good. Proceed to Test Step 5.

Not OK - At least one of wires does not have continuity.

Repair: Repair the wiring and/or the connectors. If necessary, replace the wiring and/or connectors.
Ensure that all of the seals are properly installed. Ensure that the connectors are properly engaged.
Verify that the repair has eliminated the original problem.

STOP

Test Step 5. Check the Wiring for the Cat Data Link for an Short Circuit

A. Measure the resistance between terminal J1-8 and all of the other terminals on the J1 connector.
Measure the resistance between terminal J1-8 and the ground strap for the ECM.

B. Measure the resistance between terminal J1-9 and all of the other terminals on the J1 connector.
Measure the resistance between terminal J1-9 and the ground strap for the ECM.

Expected Result:

All of the resistance measurements indicate an open circuit.

Results:

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OK - All of the resistance measurements indicate an open circuit.

Repair: Perform the following procedure:

1. Reconnect the J1 and J18 connectors.

2. Switch the 16 amp circuit breaker ON. Set the engine control to the STOP mode.

3. Look for an active 1042-09 diagnostic code.

If the code does not recur, the problem appears to be resolved. The original problem was
probably caused by a poor electrical connection. STOP.

4. If the 1042-09 code remains active, there may be a problem with the ITSM or with the ECM. It
is unlikely that the ITSM or the ECM has failed. Exit this procedure and perform this
procedure again. If the code remains active, perform the following procedure:

5. Temporarily install a new ITSM. Refer to Troubleshooting, "Replacing the ITSM". If the
problem is resolved with the new ITSM, install the original ITSM and verify that the problem
returns. If the new ITSM operates correctly and the original ITSM does not operate correctly,
replace the original ITSM. Refer to Troubleshooting, "Replacing the ITSM". If the problem is
not resolved with a new ITSM, install the original ITSM. Continue with this procedure.

6. Temporarily install a new ECM. If the new ECM operates correctly, the problem is resolved. If
the new ECM does not operate correctly, install the original ECM. Refer to Troubleshooting,
"Inspecting Electrical Connectors".

STOP

Test Step 6. Create an Open Circuit

A. Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.

B. Disconnect the connector for the thermocouple with the "short circuit" diagnostic code.

C. Switch the 16 amp circuit breaker ON. Set the engine control to the STOP mode.

D. Access the "Active Diagnostic" screen for the ITSM on Cat ET. Allow a minimum of 30 seconds for
any diagnostic codes to be generated.

Expected Result:

There is an active "open circuit" diagnostic code for the disconnected thermocouple.

Results:

Yes - There is an active "open circuit" diagnostic code for the disconnected thermocouple. The ITSM
and the harness are OK.

Repair: Perform the following procedure:

1. Thoroughly inspect the thermocouple's connectors. Ensure that the connectors and the seals are
in good condition.

2. Reconnect the thermocouple's connectors and check for an active "short circuit" diagnostic
code.

If the "short circuit" diagnostic code becomes active again, there is a problem with the
thermocouple.

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3. Disconnect the suspect thermocouple and connect a thermocouple that is known to be good.
Do not install the thermocouple into the engine yet.

4. Check for an active "short circuit" diagnostic code.

If the diagnostic code is not generated with the good thermocouple, remove the suspect
thermocouple from the engine. Install the good thermocouple.

5. Clear the logged diagnostic codes.

STOP

No - There is not an active "open circuit" diagnostic code for the disconnected thermocouple. There
is a short circuit between the harness for the thermocouple and the ITSM. Proceed to Test Step 8.

Test Step 7. Create a Short Circuit

A. Fabricate a jumper wire that is approximately 100 to 150 mm (4 to 6 inches) long with Deutsch
terminals on both ends.

B. Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.

C. Disconnect the connector for the thermocouple with the "open circuit" diagnostic code.

D. Install the jumper wire into terminal A and terminal B on the harness connector from the ITSM.

E. Switch the 16 amp circuit breaker ON. Set the engine control to the STOP mode.

F. Access the "Active Diagnostic" screen for the ITSM on Cat ET. Allow a minimum of 30 seconds for
any diagnostic codes to be generated. Observe the "Active Diagnostic" screen.

G. Remove the jumper wire and observe the "Active Diagnostic" screen. Allow a minimum of 30
seconds for any diagnostic codes to be generated.

Expected Result:

When the jumper wire was installed, a "short circuit" diagnostic code was generated. When the jumper wire
was removed, the "open circuit" diagnostic code recurred.

Results:

Yes - When the jumper wire was installed, a "short circuit" diagnostic code was generated. When the
jumper wire was removed, the "open circuit" diagnostic code recurred. The ITSM and the harness are
OK.

Repair: Perform the following procedure:

1. Thoroughly inspect the thermocouple's connectors. Ensure that the connectors and the seals are
in good condition.

2. Reconnect the thermocouple's connectors and check for an active "open circuit" diagnostic
code.

If the "open circuit" diagnostic code becomes active again, there is a problem with the
thermocouple.

3. Disconnect the suspect thermocouple and connect a thermocouple that is known to be good.
Do not install the good thermocouple into the engine yet.

4. Check for an active "open circuit" diagnostic code.

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If the diagnostic code is not generated with the good thermocouple, remove the suspect
thermocouple from the engine. Install the good thermocouple.

5. Clear the logged diagnostic codes.

STOP

No - When the jumper wire was installed, the "open circuit" diagnostic code recurred. There is
probably an open circuit in the harness between the ITSM and the connector for the thermocouple.

Repair: Remove the jumper wire.

Proceed to Test Step 8.

Test Step 8. Check the ITSM

A. Fabricate a jumper wire that is approximately 100 to 150 mm (4 to 6 inches) long with Deutsch
terminals on both ends.

B. Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.

C. Disconnect the P40 plug from the ITSM. Thoroughly inspect the J40/P40 connectors. Ensure that the
connectors are in good condition.

D. Switch the 16 amp circuit breaker ON. Set the engine control to the STOP mode.

Note: When the J40/P40 connectors are disconnected, an active "open circuit" diagnostic code will
be generated for all of the thermocouples that are associated with the ITSM. This is normal. Only pay
attention to the diagnostic codes for the suspect thermocouple.

E. Access the "Active Diagnostic" screen for the ITSM on Cat ET. Allow a minimum of 30 seconds for
any diagnostic codes to be generated. Observe the "Active Diagnostic" screen.

F. Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.

G. Install the jumper wire into the terminals for the suspect sensor on the J40 connector. For
identification of the terminals, refer to Illustration 1.

H. Switch the 16 amp circuit breaker ON. Set the engine control to the STOP mode. Observe the
"Active Diagnostic" screen. Allow a minimum of 30 seconds for any diagnostic codes to be
generated.

Expected Result:

When the J40/P40 connectors were disconnected, an "open circuit" diagnostic code was generated for the
suspect sensor. When the jumper wire was installed, a "short circuit" diagnostic code was generated.

Results:

Yes - When the J40/P40 connectors were disconnected, an "open circuit" diagnostic code was
generated for the suspect sensor. When the jumper wire was installed, a "short circuit" diagnostic
code was generated. The ITSM is OK. There is a problem in the harness between the ITSM and the
connector for the suspect thermocouple.

Repair: Remove the jumper wire. Repair the harness, when possible. If the wiring harness from the
thermocouples to the ITSM requires repair, replace the harness in order to ensure reliable operation.

All of the wiring from the thermocouples to the ITSM must be type K. The polarity of the wires from
each thermocouple to the ITSM must be maintained in order for the ITSM to read the correct
temperatures.

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After the repairs are complete, clear the logged diagnostic codes and verify that the problem is
resolved.

STOP

No - Either of the following results or both of the results occurred: When the J40/P40 connectors
were disconnected, an "open circuit" diagnostic code was not generated for the suspect sensor. When
the jumper wire was installed, a "short circuit" diagnostic code was not generated.

Repair: Perform the following procedure:

1. Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.

2. Remove the jumper wire. Disconnect the P18 connector from the ITSM.

3. Connect an ITSM that is known to be good to the P18 plug from the terminal box. Connect the
P40 plug to the good ITSM. Make sure that the good ITSM has the correct flash programming.
Refer to Troubleshooting, "Replacing the ITSM".

4. Switch the 16 amp circuit breaker ON. Set the engine control to the STOP mode. Observe the
"Active Diagnostic" screen. Allow a minimum of 30 seconds for any diagnostic codes to be
generated.

5. Verify that no diagnostic codes are generated with the good ITSM.

6. Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.

7. Reconnect the original ITSM to the P18 plug from the terminal box. Reconnect the P40 plug to
the original ITSM.

8. Verify that the diagnostic code recurs with the original ITSM.

9. Replace the ITSM. Refer to Troubleshooting, "Replacing the ITSM".

STOP

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