GMK ET Exhaust Settings
GMK ET Exhaust Settings
Page 1 of 57
Shutdown SIS
Previous Screen
Troubleshooting
C9.3 Tier 4 Interim Engines
Media Number -KENR6848-20 Publication Date -01/08/2015 Date Updated -26/08/2015
i06217218
Override Parameters
Purpose
The override parameters screen has multiple overrides. The parameters control various functions on the
engine and CEM. These functions and features allow the technician to troubleshoot different engine
systems.
Cat ET Location
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Illustration 1 g03136981
Test Operation
This override will energize the exhaust balance valve solenoid to on or off. This override will be used when
troubleshooting the exhaust balance valve.
This override activates the output for the heated nozzle in order to clean the nozzle. The output remains
activated for approximately 1 hour. The engine coolant temperature must be greater than 60° C (140° F).
The heat cycle will wait for an active regeneration to complete before starting. Once the override has been
activated, the heat cycle will automatically start as soon as conditions have been met and cannot be
deactivated. It could take up to 8 minutes for conditions to be met for the heat cycle to turn on after being
activated by the override. The heat cycle stops if the engine is stopped. The heat cycle continues when the
engine is started. Active regenerations will not occur until the heat cycle is complete. This override will be
used if a system malfunction was not allowing current to flow to ARD nozzle heater. Lack of current flow
could be caused by a blown fuse, broken heater wire, and other damaged components.
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N/A
This override is used to activate the ether injection solenoid circuit to ensure that it is working properly.
The ether canister must be removed during testing of the ether solenoid circuit.
This override will allow the CRS pump to provide fuel to the CEM. This override will be used when
pressure testing the CRS pump.
This override is used to cycle the position of the diverter valve on the CRS pump. The diverter valve
changes the path of the fuel between the engine and the CEM.
This override when Activated, will ignore any fault code from the DPF Delta P sensor. This override will
be used when using the DPF crack detection procedure.
The ECM sends a command to the ARD air valve to open to a specified percentage. The override is used to
check the operation of the valve while disassembled.
The "System Troubleshooting Settings" screen will allow overrides to be enabled. The overrides will
remain active even if the screen is exited.
Cat ET Location
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Illustration 2 g03146182
Test Operation
This override will energize the CRS spark system to on or off. This override will be used when
troubleshooting the ARD ignition system.
Aftertreatment Override
This override will allow the user to perform a regeneration that is similar to the operator using the force
switch.
Note: This override does not have any enhanced diagnostic ability. All regeneration system troubleshooting
should utilize the service tests and not this override.
This override will allow the user to disable the injectors from activating when performing certain
troubleshooting procedures.
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The purpose of this screen is to show all of the active diagnostic codes.
Cat ET Location
Illustration 3 g03146216
Reset All
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Troubleshoot Code
This tab is currently not available for Tier 4 engines. Refer to the Troubleshooting guide.
Troubleshoot Symptom
This tab is currently not available for Tier 4 engines. Refer to the Troubleshooting guide.
The purpose of this screen is to show all of the logged diagnostic codes.
Cat ET Location
Illustration 4 g03146741
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Clear
Clear All
Troubleshoot Code
This tab is currently not available for Tier 4 engines. Refer to the Troubleshooting guide.
Troubleshoot Symptom
This tab is currently not available for Tier 4 engines. Refer to the Troubleshooting guide.
The purpose of this screen is to show all of the active event codes.
Cat ET Location
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Illustration 5 g03146780
Reset All
This tab will reset all of the active codes. Some of the event codes will "latch" to active status. Repairing
the system will not "unlatch" the event codes and the event codes must be reset with Cat ET.
The purpose of this screen is to show all of the logged event codes.
Cat ET Location
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Illustration 6 g03146802
Clear
Clear All
Troubleshoot Code
This tab is currently not available for Tier 4 engines. Refer to the Troubleshooting guide.
Troubleshoot Symptom
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This tab is currently not available for Tier 4 engines. Refer to the Troubleshooting guide.
Diagnostic Tests
Cat ET diagnostic tests are listed below.
The test allows a quantity of fuel to flow through the ARD fuel supply lines by enabling the electric
priming/ARD fuel pump, and activating the pilot and main fuel valves until it senses that there is consistent
and adequate fuel pressure on the main and pilot fuel control pressure signals.
The purpose of the injector solenoid test is to diagnose injector wiring and injector solenoid functionality.
Cat ET Location
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Illustration 7 g03146818
Test Operation
This test identifies an open circuit or a short circuit in the circuit for the injector solenoids. The test
activates the injector solenoids one at a time while the engine is not running. A good solenoid will create an
audible click when the solenoid is activated. Cat ET indicates the status of the solenoid as "OK", "Open", or
"Short".
The cylinder cutout test allows one cylinder or multiple cylinders to be cut out. The cylinder cutout test is
useful when troubleshooting poor engine performance or a suspected injector failure
Cat ET Location
Test Operation
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The cylinder cutout test disables the injector by not providing the injector pulse to the solenoid. The
cylinder cutout test can be performed on one injector or multiple injectors at once.
Wiggle Test
Purpose
The purpose of the Wiggle Test is to detect intermittent electrical faults in electronic control systems. The
Wiggle Test function allows the user to determine if there is an intermittent wiring problem. The test will
indicate (by changing the value reading) which parameter moved beyond a predetermined range while
wiggling the wiring harness, sensor, or connector.
Cat ET Location
Illustration 8 g03146838
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Test Operation
This test requires that the engine is OFF and the key switch is in the ON position (or ECM energized and 0
engine speed). If the engine is started with the wiggle test active, the wiggle test will abort.
The Wiggle Test will reduce all ECM requirements to trip fault codes, making the diagnostics sensitive.
Under normal operation some fault codes need multiple occurrences before the code will log. But during
this test the fault codes will trip the first time.
The mechanic wiggles and shakes the wiring to see if codes go active. An audible alarm is also activated if
the ECM sees any parameter change state electrically. Once the test has ended, the ECM returns to normal
diagnostic state.
The high-pressure fuel pump contains two assemblies for pressurizing fuel. Each assembly contains a
solenoid. This test checks each solenoid to make sure that the solenoids are working properly.
Cat ET Location
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Illustration 9 g03146848
Test Operation
During the Fuel Rail Pump Solenoid Test, the ECM pulses 105-volt to each solenoid. The pulses are sent at
the proper time and for the correct duration for a given engine load and speed. The ECM monitors the
current flow through the circuit for each solenoid. If the current flow is too high or too low, the ECM
activates one of the following diagnostic codes:
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The Fuel System Verification Test compensates for wear of the internal components of each injector over a
time. Internal component wear contributes to lower volumes of fuel being delivered into the cylinder.
Injector wear also increases the amount of leakage past each injector back to the fuel tank. This test
evaluates the health of each injector.
Cat ET Location
Illustration 10 g03146891
Test Operation
The engine ECM determines whether the injector is delivering the correct volume of fuel into the cylinder.
Also the engine ECM determines if the injector is delivering a low volume of fuel into the cylinder based
on Valve Closing Time. Valve Closing Time is the difference between the time the engine ECM stops
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sending current to the injector solenoid and the time the valve takes to return to the valve seat. When the
test is performed, Cat ET indicates the status of each injector as "Success" or "Failed".
Note: Perform the Fuel System Verification Test after an injector is replaced. Also perform when a -2 or -7
code is active.
The ARD ignition test is used when completing maintenance to the ARD system, or for diagnosing a failed
ignition event, or for loss of combustion.
Cat ET Location
Illustration 11 g03147036
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Test Operation
The technician can initiate an ARD Ignition Test below 80 percent soot level. The test is a shortened
regeneration (approx. 4 minutes). The test checks all the components of ARD system. The ARD ignition
test checks the functionality of the system to verify that ignition has occurred and combustion is
maintained. The ARD Ignition test also actuates the Main Fuel Solenoid (If Equipped).
The Fuel System Functional Test contains four separate tests that evaluate various aspects of the common
rail fuel system. The test is a self-guided test that will advance to the next test in the series if the current test
passes. If a test in series fails, the test will abort.
Cat ET Location
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Illustration 12 g03147340
Test Operation
• The Fuel Pump Gear Installation Test evaluates if the high-pressure fuel pump was installed
correctly.
• The Fuel Rail Low Pressure Test checks for leaks at low rail pressure. The test momentarily cuts out
pumping and injection and measures the resulting rail pressure drop. The test then calculates the fuel
quantity leaving the rail and compares to the expected results.
• The Fuel Rail High Pressure Test checks for fuel leaks at high rail pressure. The test momentarily
cuts out pumping and injection and measures the resulting rail pressure drop. The test then calculates
the fuel quantity leaving the rail and compares to the expected results.
• The Fuel Pump Flow Pump Test assesses adequate fuel pump flow. The test measures rail pressure
response during a single pump event while fuel injection is disabled.
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This test determines if an injector is causing an engine performance problem. The ability of each injector to
deliver a certain amount of fuel is tested.
Cat ET Location
Illustration 13 g03147378
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Test Operation
Each injector is tested at various rail pressures. This test runs for a maximum of 9 minutes. The test helps
identify problems with injectors at higher rail pressures.
Method to determine the EGR System health and determine if the EGR system is functioning properly. The
test will exercise the EGR valve, and check for exhaust gas flow.
Cat ET Location
Illustration 14 g03137051
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Test Operation
The test is conducted with the engine running at a constant speed and load with machine/vehicle speed
zero.
• EGR Response Test: Known conditions are established for the engine. The EGR valve is commanded
from open to closed. The response is checked for the EGR Delta Pressure Sensor, EGR Absolute
Pressure Sensor, and fuel quantity. Each input has a unique response time, which will be compared to
a threshold. The commanded EGR valve positions are held for a fixed amount of time to allow the
inputs to stabilize. This procedure is repeated several times to increase accuracy and repeatability.
• EGR Valve Sweep: Known conditions will be established for the engine. The EGR valve is swept
from open to closed repeatedly to check for satisfactory response of the EGR flow.
The purpose of the ARD air system service test is to determine if the ARD air valve is controlling the
airflow as commanded by the controller. This test will determine if the ARD air valve is functioning
properly.
Cat ET Location
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Illustration 15 g03137054
Test Operation
The ARD air valve is cycled while the ECM monitors boost and aftertreatment secondary air pressure. The
ECM looks for a specific amount of drop in boost and aftertreatment secondary air pressure when the valve
is actuated. The values must be higher than the threshold in order to pass the test.
The ARD Nozzle Heater Circuit Test allows the technician to verify that the heated nozzle and nozzle
circuit are functioning properly.
Cat ET Location
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Test Operation
The test cycles the ARD fuel nozzle heater on for 3 minutes, or until the test is aborted by the technician.
The 3 minutes will give the technician time to perform an electrical check on the heater. Perform the
electrical test by hooking a current probe around the heater wire to verify that the heater is getting the
proper current. Engine speed must be present while this test is running to allow coolant to circulate through
the ARD head. Once the current has been measured, the test can be aborted.
Calibrations
Cat ET calibrations are listed below.
Injector trim files calibrate each injector. The injectors are calibrated so the injectors will deliver a precise
amount of fuel at the exact time needed.
Cat ET Location
Calibration Operation
Caterpillar tests each injector to verify the accuracy of the injector duration and timing. If the injectors do
not pass, the injectors are not used. If the injectors do pass, trim files are created and the injectors are
installed. The trim file adjusts the duration and timing of each injector, so the injectors all function the
same. When new injectors are installed, the technician records the serial numbers of each injector and
searches for the injectors in SIS Web. The trim files can be downloaded and stored on a pc. The technician
loads the trim file for each injector into the ECM.
In Illustration 16 you can see each injector that falls in the box is a good injector that passed the tests.
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Illustration 16 g02157706
In Illustration 17 you can see that the trim files have been applied. The trim files correct the injectors back
to nominal so the injectors all inject the same amount at the same time.
Illustration 17 g02157717
Note: If the injectors fall outside of the main window, the injectors are scrapped.
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Illustration 18 g03137056
Illustration 19 g03147463
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2. Select Air Inlet Temperature Sensor Installation Calibration and click Start.
Illustration 20 g03147678
4. Click Yes and the engine should be placed under a relatively high load and high engine speed
operating condition. This does not necessarily have to be the highest possible load the installation
could see. If loading the engine is not possible increase the engine speed to 1800 RPM.
5. Enter the ambient temperature from thermocouple or hand held thermometer, then click OK. The
ambient temperature must be below the Air Inlet Temperature displayed in the window. Measure the
ambient temperature in the shade away from hot air flow generated from the fan. Make sure to use
Celsius if Cat ET is set up in Celsius.
6. The engine should be placed under a relatively high load and high engine speed for 2 minutes then
click Next. If loading the engine is not possible, increase the engine speed to 1800 RPM for 2
minutes then click Next.
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Illustration 21 g03147742
7. Click Yes and decrease the engine speed to low idle (600 - 700 RPM) and remove any load from the
engine.
Illustration 22 g03147748
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8. Enter the ambient temperature from thermocouple or hand held thermometer, then click OK. The
ambient temperature must be below the Air Inlet Temperature displayed in the window. Measure the
ambient temperature in the shade away from hot air flow generated from the fan. Make sure to use
Celsius if Cat ET is set up in Celsius.
9. Run the engine at low idle (600 - 700 RPM) and remove any load from the engine for 2 minutes and
then click Next.
Illustration 23 g03327553
10. The calibration value has been calibrated. Write down the calibration so you can enter the calibration
value in the configuration parameters. Next, click Accept.
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Illustration 24 g03147698
11. Calibration Successful, ignore "Conditions Not Met" displayed in above window for Engine Intake
Manifold Mass Flow Rate. Go to Configuration, select System Settings and enter the calibrated value
into the Air Inlet Temperature Sensor Calibration. You will need Factory Passwords to program this
value.
Service Procedures
Cat ET service procedures are listed below.
Dyno Mode
Purpose
Dyno Mode is used to run an engine on a dyno without derates or diagnostic trouble codes tripping from
missing machine components. Normally, while in chassis an ECM is looking for inputs from various
machine components, like the transmission ECM or body ECM. Dyno Mode does not require the CEM to
be installed. If the ECM does not see the inputs, the ECM assumes that something is wrong and sets a
diagnostic trouble code.
Cat ET Location
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Illustration 25 g03147687
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Illustration 26 g03137155
The engine is installed on the dyno and the technician selects Dyno mode. Dyno mode tells the engine
ECM that the engine is on a dyno and the ECM ignores all the normal inputs from the machine. Once in
dyno mode, if the engine has multiple power ratings the highest rating should be selected.
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Illustration 27 g03137154
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Illustration 28 g03137153
This regeneration is used to clean 100 percent of the soot out of the DPF prior to performing a diesel
particulate filter cleaning.
Cat ET Location
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Illustration 29 g03137152
This regeneration has a fixed length of time that the regeneration heats up the DPF and burns out soot that
has built up during operation. This service procedure is done before an ash servicing has taken place, and
the regeneration makes the ash cleaning more effective.
Manual Regenerations are used by the technician to regenerate the DPF and troubleshoot the aftertreatment
system.
Cat ET Location
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Illustration 30 g03137150
This type of regeneration lasts a minimum of 10 minutes, and soot loading is at 0 percent. If a problem is
encountered during the regeneration, the diagnostics are tuned to alert the technician. This regeneration also
tests the ARD nozzle for plugging by comparing desired and actual DPF inlet temperature.
The engine ash model must be reset whenever the filter is cleaned or replaced. Reseting the ash model
places the DPF ash volume back to the "Clean State". The resetting will allow the regeneration of the DPF
to function properly.
Cat ET Location
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Illustration 31 g02477962
2. Select "Service" from the top menu and highlight "Service Procedures".
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Illustration 32 g02477961
3. From the "Service Procedures" menu, highlight "DPF Ash Service". Select "Start".
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Illustration 33 g02495621
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Illustration 34 g02477958
Illustration 35 g02477960
5. Choose the correct replacement type of diesel particulate filter in the menu that appears. The types of
replacements for the diesel particulate filter are the following:
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Illustration 36 g02495643
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Illustration 37 g02478024
6. Once the reset is completed, a log of the reset is captured and visible as a new row of information in
the DPF ash service screen. Resetting the engine ash model does not reset the soot level.
7. Perform a "Manual DPF Regeneration" with Cat ET to reset the soot level
The ARD Fuel Line Flush enables the service technician to flush potential debris from the ARD fuel lines.
The flushing helps to prevent the ARD nozzle from becoming plugged after being serviced.
Cat ET Location
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Illustration 38 g03137128
The ARD Fuel Line Flush allows a quantity of fuel to flow through the ARD supply lines. The flush is
accomplished by enabling the electric priming/ARD fuel pump, and activating the pilot and main valve.
The ECM cycles the pilot and main solenoid on for 10 seconds and off for 10 seconds. The ECM repeats
the cycles four times. The pilot and main lines MUST be disconnected from the ARD head and allowed to
flow fuel into a container. The container must be able to hold 5 gal of fuel for this procedure.
Note: DO NOT ATTEMPT TO RUN THIS TEST WITH THE FUEL LINES STILL CONNECTED.
The DPF could be damaged.
Cat ET Location
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Illustration 39 g03137126
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Illustration 40 g03137124
Column Headings
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Time - Triggered because a specified amount of time has elapsed since a complete regeneration
occurred
What the ECM configuration file was programmed to at the time of the regeneration.
Automatic Low Speed Regeneration Only - Stationary or forced regenerations are the only
regeneration types allowed
Status values 1 through 3 are indicative of a high speed regeneration. Status values 4 and above are
indicative of a low speed regeneration.
Note: Industrial Engines will only show a status value of a 2 or a 5 in this column. Status value 5
means that low speed or high speed regenerations are allowed. Status value 2 means that only high
speed regenerations are allowed.
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The machine hour reading when the regeneration stopped. The regeneration could stop when the
regeneration was successfully completed or when the regeneration was stopped by the operator.
Cat ET Snapshots
Snapshots allow the user to view data in Cat ET approximately 9.5 seconds before and 3.5 seconds after the
time the diagnostic trouble code was recorded.
Illustration 41 g03137101
1. Select the "Information" tab. Select the "Snapshot" tab, then select the "Viewer" tab.
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Illustration 42 g03137100
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Illustration 43 g03137099
Illustration 44 g03137098
4. Select the channels to view and add the channels to the group. Select "OK".
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Illustration 45 g03137096
5. The sliding time bar indicates when the diagnostic trouble code was recorded. Data can be viewed
9.5 seconds before and 3.5 after the time the code was recorded .
Illustration 46 g03137095
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6. Select the "View Graph" tab for graphic illustrations. Select the channels you want to view, and
select "OK".
Illustration 47 g03137092
Histogram Screens
Tab Functions At Bottom of Screen
Histograms
Clear
Clear All
This tab will clear the current histogram data for this key cycle.
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This labels each bar in the graph as the mouse pointer is moved over the bar.
Screen Shots
Illustration 48 g03137091
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Illustration 49 g03137090
Illustration 50 g03137088
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Illustration 51 g03137087
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Illustration 52 g03137086
The amount of engine hours operated at indicated intake manifold air temperature.
Illustration 53 g03137084
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Illustration 54 g03137083
This screen is used to help understand the operator use of the disable switch and at what soot load the regenerations take place.
Manual disable status 0 = regenerations allowed due to switch position. Manual disable status 1= regenerations not allowed due
to switch position.
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Illustration 55 g03137081
This screen is used to illustrate load percentage at the current engine speed. This screen can be helpful in understanding how the
engine is being used. The screen can also be used for comparison between similar machines and/or operators.
Illustration 56 g03137080
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This histogram is populated when the engine system has calculated a condition in which high exhaust temperatures are present.
A fault code will not be logged when the system calculates a high exhaust temperature condition, but will activate a derate to
the engine in order to protect the engine system. This is normal under most circumstances and no additional troubleshooting is
necessary. Refer to Troubleshooting, "Exhaust Temperature is High" for additional information.
Illustration 57 g03137079
There are certain engine conditions that put the engine in danger of turbocharger overspeed. The engines are calibrated and
certified up to a certain altitude and ambient temperature limit. If the engine is operated outside this limit, the engine is more
likely to experience overspeed of the turbo. In other words, the turbo has to work harder to maintain the desired boost pressure.
This is normal under most circumstances and no additional troubleshooting is necessary.
Copyright 1993 - 2017 Caterpillar Inc. Tue Aug 22 16:33:15 PDT 2017
All Rights Reserved.
Private Network For SIS Licensees.
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