C9 On-highway Engines Caterpillar

Use this procedure to troubleshoot the following codes:

Illustration 1 and Illustration 2 show an overview of the troubleshooting procedure. Follow the steps in the order the steps are listed.

Illustration 1	g02722405

Illustration 2	g02722409

Test Step 1. Determine the Type of Cleaning System for the Nozzles Inside the ARD Combustion Head

Illustration 3	g01976876
Typical ARD combustion head (1) Electrical connector for the heated nozzle (ARD combustion head with a heated nozzle) (2) Air line for the pressurized air (ARD combustion head that uses pressurized air for cleaning the nozzles)

1. Determine the type of cleaning system for the nozzles inside the ARD combustion head.

Results:

• The ARD purge air system is used to clean the nozzles. -

  Repair: Contact your local Caterpillar Technical Communicator for information on updating to the heated nozzle system.

  STOP

• An electric heating element is used to clean the nozzles. - Proceed to Test Step 2.

Test Step 2. Check for Associated Diagnostic Trouble Codes

1. Establish communication between the Caterpillar Electronic Technician (ET) and the engine ECM.

2. Table 2 lists the diagnostic trouble codes that are associated with a 3474-31 code and a 3245-15 code. Determine if any of the codes in Table 2 are present.

Results:

• An associated diagnostic trouble code is not present. - Proceed to Test Step 3.

• An associated diagnostic trouble code is present. -

  Repair: Troubleshoot the associated diagnostic code.

  STOP

Test Step 3. Perform the ARD Nozzle Heater Test

Perform an ARD Nozzle Heater (Current) - Test. Refer to System Operation and Testing and Adjusting, "ARD Nozzle Heater (Current) - Test" for the correct procedure.

1. Carefully inspect the wire leading to the ARD combustion head. Pull on the wire to verify that the wire is crimped to the terminal and that the terminal is properly installed in the connector.

2. Disconnect the connector where the connector plugs into the engine harness in order to verify that the wiring and terminals are installed correctly. Make the necessary repairs.

3. Inspect the wiring between the connectors. Look for the following problems and make the necessary repairs:
   • Damage that is caused by excessive heat

   • Damage that is caused by chafing

   • Improper routing of wiring

   • Damaged insulation

Expected Result:

The current flow is above 6.0 A for a 12 V system.

The current flow is above 3.0 A for a 24 V system.

Results:

• The current flow agrees with the above results. - The current flow is OK. Proceed to Test Step 4.

• The current flow does not agree with the above results. The current flow is low. There may be a problem with the current flow through the heater. -

  Repair: Determine the cause of the low current flow. Refer to Troubleshooting, "ARD Nozzle Heater - Test".

  STOP

Test Step 4. Perform the "Engine Air System Verification Test"

1. Perform the "Engine Air System Verification Test". Refer to Air System Verification Test for additional information on the test, if necessary.

2. Determine if the results are acceptable. Refer to Troubleshooting, "Air System Verification Test" in order to determine if the results are acceptable.

Note: The Air System Verification Test does not determine if the results are acceptable. Acceptable ranges are provided in the Troubleshooting, "Air System Verification Test".

Results:

• The results are within the acceptable range. - Proceed to Test Step 5.

• The results are not within the acceptable range. -

  Repair: Refer to the Troubleshooting, "ARD Combustion Air - Test".

  STOP

Test Step 5. Determine the Type of ARD Manifold Fuel Filter Fittings and Replace if Necessary

1. Determine if the unit has screen element filter fittings ( 323-2205 Filter Connector As and 323-2206 Filter Connector As ). The newer design fittings with sintered metal elements are 353-8397 Connector As and 353-8398 Connector As which are taller at the hex. Refer to Illustrations below to identify which filter fittings are present.

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Illustration 4	g02722400
Screen element filter fittings (A) 9 mm (0.35 inch) (B) 8 mm (0.30 inch) (3) 323-2205 Filter Connector As (4) 323-2206 Filter Connector As

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Illustration 5	g02722401
Sintered metal element filter fittings (C) 10 mm (0.40 inch) (D) 10 mm (0.40 inch) (5) 353-8397 Connector As (6) 353-8398 Connector As

2. If the earlier screen element fittings are present, replace the fuel filters in the ARD manifold. Use only part numbers 353-8397 Connector As, 353-8398 Connector As, or 353-9485 Elbow As .

Illustration 6	g02722403
The connector filters are located in the manifold for the lines to the ARD head. (7) Location of the connector filters on C15 applications (8) Location of the connector filters on certain C13 applications

Note: Check the fuel lines for leaks after the ARD combustion head and the connectors are installed. Refer to Special Instruction, REHS3412, "Inspecting the Fuel System for the Aftertreatment Regeneration Device".

Results:

• The filters were replaced. - Proceed to Test Step 6.

Test Step 6. Data Log Stationary Regeneration and Interpret the Data Log

Refer to Special Instruction, REHS3407, "Using the Caterpillar Electronic Technician (ET) Data Log" for information on using the data log.

1. Clear all active diagnostic and active event codes before starting the regeneration.

2. Configure the settings on the "General" tab according to the following information:

   Sample Rate - Enter a sample rate of 20 samples per minute.

   Duration - Enter a duration of 1 hour.

3. The data log must capture the following parameters. Create a group that contains only the following parameters, if necessary:
   • ARD Inlet Temperature

   • ARD Flame Temperature

   • ARD Outlet Temperature

   • Diesel Particulate Trap #1 Intake Temperature

   • Diesel Particulate Trap #1 Outlet Temperature

   • Diesel Particulate Trap #1 Differential Pressure

   • ARD Pilot Fuel Pressure

   • ARD Fuel Pressure

   • ARD Fuel Pressure Control Command Percentage

   • ARD Air Pressure Control Command Percentage

   • ARD Secondary Air Gas Mass Flow

   • CGI Mass Flow Rate

   • Boost Pressure

   • Engine Speed

4. Start the data log. Then, begin a stationary regeneration by selecting the following menu items on Cat ET:
   • Service

   • Service Procedures

   • Manual Diesel Particulate Filter Regeneration

   Cat ET will display a "Waiting On Requirements" window. The ECM will automatically elevate the engine speed to 1400 rpm. If the "Waiting On Requirements" window remains displayed for more than 5 minutes, abort the regeneration. Then, select the menu options again in order to start the stationary regeneration.

   The duration of the stationary regeneration depends on the soot load in the DPF. The ECM will automatically return the engine speed to low idle after the stationary regeneration is complete.

   Note: The ECM tests the nozzles for plugging after the stationary regeneration is complete. Approximately 10 minutes are required in order for the test to provide a result. A code will become active if the nozzles are plugged.

5. Stop the data log after the engine speed returns to idle.
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   Table 3

   Parameter	Target Conditions	Action
   DPF #1 Intake Temperature	Target is 583° C (1083° F), in cold conditions some CRS housings may not achieve the full 583° C (1083° F). Temperatures greater than 551° C (1025° F) should occur in all climates	Low Temperature: Refer to Troubleshooting Guide, "ARD Temperature Is Low" High Temperature: Cat ET will return fault code. Troubleshoot code. No interpretation necessary.
   DPF #1 Outlet Temperature	Outlet temperature will lag inlet temperature during the warm-up period. DPF outlet should be ±40° F of inlet by end of the 583° C (1083° F) hold.	Low Temperature: Refer to Troubleshooting Guide, "Diesel Particulate Filter Temperature Is Low" High Temperature: Refer to Troubleshooting Guide, "Diesel Particulate Filter Temperature Is High"
   ARD Pilot Fuel Pressure	When ARD Fuel Pressure Control Command Percentage is 55% or greater, pilot pressure should be in range of 1475 kPa (214 psi) to 1975 kPa (288 psi)	Low Pressure: Refer to Troubleshooting Guide, "Fuel System Pressure - Test" High Pressure: Refer to Troubleshooting Guide, "ARD Fuel Pressure Is High"
   ARD Fuel Pressure	The amount of ARD Fuel Pressure required to achieve the desired DPF Intake Temperature is a function of Engine bore size, exhaust piping, DPF configuration, and environmental conditions such as temperature and altitude. A typical C9 at standard conditions will range in ARD fuel pressure from 0 kPa (0 PSI) to 48 kPa (7 psi) to achieve 583° C (1081° F).	Low Pressure: Refer to Troubleshooting Guide, "Fuel System Pressure - Test" High Pressure: Refer to Troubleshooting Guide, "ARD Fuel Pressure Is High"
   CGI Mass Flow Rate	Some CGI Mass Flow Rate leakage through the CGI valve is typical during a forced regeneration. If CGI Mass Flow Rate is questionable perform an Air System Verification test.	Refer to Troubleshooting Guide, "Clean Gas Induction - Test"
   Flame Temperature	Flame temperature will vary greatly based on A/F ratio, environmental conditions, and CRS head.	Too Low: A 112F error code will be returned. Refer to Troubleshooting Guide, "ARD Combustion - Test" Too High: If above 1205° C (2200° F), remove, clean, and inspect. Replace if damaged.

Results:

• The regeneration completed successfully and the data log interpretation was OK. -

  Repair: If a 310 is logged and the parameters fall within the values listed in Table 3, release the truck to service.

  STOP

• The regeneration completed successfully but the data log interpretation was not OK. -

  Repair: Follow the action as determined in Table 3.

  Proceed to Test Step 7.

• The regeneration did not complete successfully. - Proceed to Test Step 7.

Test Step 7. Perform the ARD Fuel Nozzle Heater Cycle Override and Clean the ARD Flame Temperature Sensor

1. Remove the ARD flame temperature sensor.

2. Clean ARD flame temperature sensor.

3. Reinstall ARD flame temperature sensor.

4. Perform the ARD fuel nozzle heater cycle by selecting the following menus on Cat ET:

   1. "Diagnostics"

   2. "Diagnostic Tests"

   3. "System Troubleshooting Settings"

   4. "ARD Fuel Nozzle Heater Cycle"

5. Run the ARD fuel nozzle heater cycle for 1 hour.

Results:

• Heater cycle is completed - Proceed to Test Step 8.

Test Step 8. Data Log a Stationary Regeneration

1. Clear all diagnostic codes before starting the regeneration.

2. Data log a stationary regeneration.

Results:

• Regeneration completed successfully. -

  Repair: Interpret the data log in order to determine if the problem has been resolved. If a 310 is logged and if the parameters fall within the values listed in Table 3, release the truck to service.

  STOP

• Regeneration completed successfully but the data log interpretation was not OK. -

  Repair: Follow the action as determined in Table 3.

  Rerun Test Step 8

• Regeneration did not complete successfully. -

  Repair: Replace the ARD head. Repeat this Step. If the data log does not show a successful regeneration, contact the local Caterpillar Technical Communicator.

  STOP