C7.1 Engines and Generator Sets Caterpillar

ARD Failed to Ignite

Usage:

C7.1 770

Use this procedure to troubleshoot the following code:

Note: Refer to Troubleshooting, "Service Tool Features" for information about service features.

Show/hide table

Table 1
Diagnostic Trouble Codes
J1939 Code	CDL Code	Code Description	Comments
3473-31	E1025 (2)	Aftertreatment #1 Failed to Ignite	The Aftertreatment Regeneration Device (ARD) has failed to ignite. Usually, the "failed to ignite" code is accompanied by another logged code that indicates the condition that caused the failure to ignite.
Follow the troubleshooting procedure to identify the root cause of the problem.

Components for the Ignition System

The ignition coil is on the Clean Emissions Module (CEM) mounting plate. Refer to Illustration 1.

Show/hide table




Illustration 1	g06125618
CEM (typical) (1) Electrical connector to ECM (2) Relay for the ARD nozzle heater (3) ARD ignition coil (4) ARD combustion head

System Operation

The ARD ignition system has two circuits. The primary circuit is between the ECM and the ARD ignition coil. The secondary circuit is between the ARD ignition coil and the ARD spark plug. The current flow through the primary circuit indicates the condition of the primary circuit and of the secondary circuit. The ECM monitors the current flow through the primary circuit. In this way, the ECM is able to detect problems with the primary circuit and the secondary circuit.

Complete the procedure in the order in which the steps are listed.

Show/hide table

Table 2
Associated Diagnostic Trouble Codes
J1939 Code	CDL Code
102-18	E1045 (2)
3487-7	E1041 (1)
3480-15	E1050 (1)
3480-16	E1050 (2)
3480-17	E1052 (1)
3484-5	2465-5
3484-6	2465-6
3480-18	E1052 (2)
3556-7	E1070 (1)
4265-5	3180-5
4265-6	3180-6
No associated codes	A problem with the ignition circuit is the most likely cause of a logged E1025 (2) or 3473-31 code with no additional codes.

Show/hide table

Table 3
Troubleshooting Test Steps	Values	Results
1. Check for Associated Codes A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). B. If any of the associated codes in Table 2 are logged, troubleshoot the codes before continuing with this procedure.	Associated Codes	Result: An associated code is active or logged. Repair: Troubleshoot the associated codes before continuing with this procedure. Result: An associated code is not active or logged. Proceed to Test Step 2.
2. Inspect the Components Carefully following this procedure is a good way to identify wiring problems. A. Visually inspect the components for the ARD ignition system. Look for the following problems: 1. Loose connections or damaged connectors 2. Moisture on the connectors or the wiring 3. Damage that is caused by excessive heat 4. Damage that is caused by chafing 5. Improper routing of wiring 6. Damaged insulation B. Verify that each end of the ground wire is securely connected to both ground points. C. Push the boot on each end of the ignition wire. This action tests whether the clip inside the boot is connected to the spark plug and to the ignition coil. There should not be a "click" when you push the boot onto either part. If you felt a "click", the clip inside the boot was not connected. D. Pull on the end of each harness wire at the 3-pin connector for the ignition coil. This test verifies that the wire is crimped to the terminal and that the terminal is inserted into the connector.	Damaged wiring or connectors	Result: There is a problem with the wiring. A wire end is not connected or a wire is damaged. Repair: Repair the wiring. Replace parts, if necessary. Verify that the problem is resolved. If the problem is not resolved, proceed to Troubleshooting, "ARD Ignition - Test". Result: The wiring is OK. Proceed to Test Step 3.
3. Check the Current Flow to the Heating Element in the ARD Combustion Head Start the engine. Check the current flow to the heater. Refer to Systems Operation/Testing and Adjusting, "ARD Nozzle Heater (Current)- Test" for the correct procedure.	7.0 A to 14.0 A for a 12 V system or 3.5 A to 7.0 A for a 24 V system	Result: The current flow is not between 7.0 A and 14.0 A for a 12 V system. The current flow is not between 3.5 A and 7.0 A for a 24 V system. Repair: There may be a problem with the ARD nozzle. Refer to Troubleshooting, "ARD Nozzle Heater - Test". Result: The current flow is between 7.0 A and 14.0 A for a 12 V system. The current flow is between 3.5 A and 7.0 A for a 24 V system. The current flow is OK. Proceed to Test Step 4.
4. Perform the "ARD Air System Service Test" A. Reset all active codes and clear all logged codes. Use the electronic service tool to perform an "ARD Air System Service Test". Refer to Troubleshooting, "ARD Combustion Air - Test".	Test passed	Result The "ARD Air System Service Test" failed. Repair: There is a problem with the ARD combustion air. Refer to Troubleshooting, "ARD Combustion Air - Test". Result The "ARD Air System Service Test" passed. Proceed to Test Step 5.

Show/hide table




Illustration 2	g06125649
368-6232 Spark Indicator (5) Connector for spark plug (6) Spark window (7) Connector for HT ignition lead

Show/hide table

Table 4
Troubleshooting Test Steps	Values	Results
5. Check for Spark Voltage at the Spark Plug A. Disconnect the ignition wire from the spark plug. B. Connect the 368-6232 Spark Indicator between ignition wire and the spark plug. C. Use the "Aftertreatment #1 Ignition Transformer Primary Override" located in the electronic service tool to turn ON the ARD ignition system. The override is located in the "Engine #1 Aftertreatment Controller" under "System Troubleshooting Settings". D. Check for sparks in the spark indicator.	Spark	Result: There are no sparks inside the spark indicator. Turn off the ARD ignition system by disabling the override. Proceed to Troubleshooting, "ARD Ignition - Test". Result: There are sparks inside the spark indicator. Turn off the ARD ignition system by disabling the override. Proceed to Test Step 6.

Show/hide table




Illustration 3	g06125716
(8) ARD spark plug

Show/hide table

Table 5
Troubleshooting Test Steps	Values	Results
6. Clean the Components in the ARD Combustion Head A. Remove spark plug (8) from the ARD combustion head. B. Clean the ground probe inside the ARD combustion head. Run a 305-2389 Plug Bore Brush through the spark plug hole in the ARD combustion head. Run the brush through the hole several times. C. Inspect the spark plug. Look for the following faults: 1. Carbon Deposits - Use a nonmetallic cleaning pad to clean the spark plug. 2. Bent Probe - If the probe appears to be bent, replace the spark plug. Otherwise, install the original spark plug. Refer to the Specifications manual for the correct torque value. 3. Cracked Porcelain - If the porcelain appears to be cracked, replace the spark plug. Otherwise, install the original spark plug. Refer to the Specifications manual for the correct torque value. The spark plug may be damaged if the spark plug is dropped. Do not install a spark plug that has been dropped.	Spark Plug	Result: If the spark plug probe is bent, cracked, or has been dropped. Repair: Replace the spark plug. Result: The components are clean. The spark plug is not damaged. Install the spark plug. Proceed to Test Step 7.

Show/hide table




Illustration 4	g06125733
(9) Flame detection temperature sensor

Show/hide table

Table 6
Troubleshooting Test Steps	Values	Results
7. Clean the Flame Detection Temperature Sensor A. Remove the flame detection temperature sensor (9). B. Clean the flame detection temperature sensor. Use a nonmetallic cleaning pad to clean the sensor.	Sensor	Result: The components are clean. The flame detection temperature sensor is not damaged. Install the flame detection sensor. Proceed to Test Step 8. Result: The flame detection temperature is damaged. Replace flame detection temperature sensor. Proceed to Test Step 8.
8. Check the ARD for Correct Operation A. Reset all active codes and clear all logged codes. Use the electronic service tool to perform an "ARD Ignition Test" to verify that the problem is resolved. The ARD Ignition Test cannot be performed if the DPF soot loading is above 80%. When the DPF soot loading is above 80%, the Manual DPF Regeneration must be performed using the electronic service tool.	Successful test	Result: The test is not successful. There are additional codes. Repair: Troubleshoot the additional codes. Refer to Troubleshooting for the correct procedure. Verify that the problem is resolved. Result: The test is successful. Proceed to Test Step 11. Result: The test is not successful. Proceed to Test Step 9.

Show/hide table




Illustration 5	g06126133
Components of the ARD combustion head (10) ARD pilot filter connector

Show/hide table

Table 7
Troubleshooting Test Steps	Values	Results
9. Replace the Pilot Filter Connector at the ARD Combustion Head A. Flush the ARD fuel system and replace pilot filter connector (10) at the ARD combustion head. Refer to Systems Operation/Testing and Adjusting, "Fuel System - Flush" for additional information. B. Reset all active codes and clear all logged codes. Perform the "ARD Ignition Test" using the electronic service tool and verify that there are no fuel leaks. Refer to System Operation/Testing and Adjusting, "ARD Fuel System - Test". The ARD Ignition Test cannot be performed if the DPF soot loading is above 80%. When the DPF soot loading is above 80%, the Manual DPF Regeneration must be performed using the electronic service tool.	Test	Result: The test is successful. Proceed to Test Step 11. Result: The test is not successful. Proceed to Test Step 10. Result: The test is not successful. There are additional codes. Repair: Troubleshoot the additional codes. Refer to Troubleshooting for the correct procedure. Verify that the problem is resolved.

Show/hide table




Illustration 6	g06126139
(11) Fouled slot

Show/hide table




Illustration 7	g06126141
(12) Acceptable soot accumulation

Show/hide table

Table 8
Troubleshooting Test Steps	Values	Results
10. Inspect ARD Swirl Plate A. Remove ARD head. Refer to Disassembly and Assembly, "Combustion Head Group (ARD) - Remove and Install - Clean Emissions Module" for the proper procedure to remove the ARD combustion head. Soot accumulation is normal. Slot fouling is defined as more than half the inner row slots being completelyblocked. Partially blocked inner row slots are normal and do not affect regeneration performance. Refer to Illustrations 6 and 7 to verify if the swirl plate is fouled. B. Inspect the swirl plate for fouled slots. Refer to Illustrations 6 and 7 to verify if the swirl plate is fouled.	Swirl Plate	Result: The swirl plate is fouled. Clean the swirl plate. Refer to Testing and Adjusting, "Swirl Plate (ARD Combustion) - Inspect/Clean". Repair: Reset all active codes and clear all logged codes. Perform the "ARD Ignition Test" in the electronic service tool and verify that there are no fuel leaks. The ARD Ignition Test cannot be performed if the DPF soot loading is above 80%. When the DPF soot loading is above 80%, the Manual DPF Regeneration must be performed using the electronic service tool. Proceed to Test Step 11. Result: The swirl plate is not fouled. Repair: Replace the ARD combustion head. Refer to Disassembly and Assembly, "Combustion Head - Remove and Install". Reset all active codes and clear all logged codes. Perform the "ARD Ignition Test" in the electronic service tool and verify that there are no fuel leaks. The ARD Ignition Test cannot be performed if the DPF soot loading is above 80%. When the DPF soot loading is above 80%, the Manual DPF Regeneration must be performed using the electronic service tool. Proceed to Test Step 11.
11. Perform a "Manual DPF Regeneration" This test must be performed through the electronic service tool. The electronic service tool enhances the diagnostics during the service test. A. Clear all diagnostic codes. B. Start the engine. Allow the engine to idle for 3 minutes. Do not use the operators switch for stationary regeneration. The service tests provide enhanced diagnostics that are necessary for proper troubleshooting and repair. C. Start a "Manual DPF Regeneration" in the electronic service tool.	Successful test	Result: The "Manual DPF Regeneration" completed successfully. There are no additional codes. Return the unit to service. Result: The "Manual DPF Regeneration" did not complete successfully. There are additional codes. Repair: Troubleshoot the additional codes. Refer to Troubleshooting for the correct procedure. Verify that the fault has been eliminated. If the fault is still present, contact the Dealer Solutions Network (DSN).