C9 On-highway Engines Caterpillar

ARD Failed to Ignite

Usage:

C-9 MFF

System Operation Description:

Use this procedure to troubleshoot the following code:

Show/hide table

Table 1
Diagnostic Trouble Codes for the Ignition System for the Aftertreatment Regeneration Device (ARD)
J1939 Code	Description	Comments
3473-31	Aftertreatment #1 Failed to Ignite	The ARD has attempted to ignite several times. All of the attempts were unsuccessful. Approximately 10 minutes are required for each attempt. A "failed to ignite" code may not indicate that there is a problem with the ignition system. There may be a problem with another system such as combustion air or fuel. Usually, the "failed to ignite" code is accompanied by another logged code that indicates the condition that caused the failure to ignite. The first Test Step in this procedure contains a Table that lists the additional codes.
Follow the troubleshooting procedure in order to identify the root cause of the problem.

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

Show/hide table




Illustration 1	g02721510

Show/hide table




Illustration 2	g02721515

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

Show/hide table




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)

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 the 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

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

Table 2 lists the diagnostic trouble codes that are associated with a 3473-31 code. Determine if any of the codes in Table 2 are present.

Show/hide table

Table 2
Associated Diagnostic Trouble Codes
Suspect Parameter Number (SPN)	Failure Mode Identifier (FMI)	Description
ARD Ignition System
4265	6	Aftertreatment #1 Transformer Secondary Output : Current Above Normal
Combustion Air System
3832	15	Aftertreatment #1 Secondary Air Mass Flow : High - Least Severe (1)
3832	17	Aftertreatment #1 Secondary Air Mass Flow : Low - Least Severe (1)
3487	7	Aftertreatment #1 Air Pressure Control : Not Responding Properly
Fuel System for the ARD
3480	16	Aftertreatment #1 Fuel Pressure #1 : High - Moderate Severity (2)
4077	16	Aftertreatment #1 Fuel Pressure #2 : High - Moderate Severity (2)
4077	17	Aftertreatment #1 Fuel Pressure #2 : Low - Least Severe (1)
4077	18	Aftertreatment #1 Fuel Pressure #2 : Low - Moderate Severity (2)
Clean Gas Induction System (CGI)
520192	15	CGI Mass Flow : High - Least Severe (1)
520192	16	CGI Mass Flow : High - Moderate Severity (2)
Nozzle
3556	7	Aftertreatment Fuel Injector #1 : Not Responding Properly

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.

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

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.

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. Check for Spark Voltage at the Spark Plug

Note: A 305-2391 Spark Indicator must be used to troubleshoot the ignition system for the Aftertreatment Regeneration Device (ARD). Other types of spark indicators provide incorrect indications.

Show/hide table




Illustration 4	g01978667
305-2391 Spark Indicator (3) End of the spark indicator (4) Location on the tool (5) Clip on the adjustable end of the spark indicator (6) "20" indication on the tool

Turn clip (5) until the tip of the threaded rod (4) is set to location (6) .

Disconnect the ignition wire from the spark plug.

Show/hide table




Illustration 5	g01978668
Typical configuration (7) Ignition wire (8) Ground point

Connect the spark indicator between ignition wire (7) and ground point (8) .

The ARD ignition system must operate for a minimum of 60 seconds to ensure that the spark remains consistent. Use the ARD Ignition Transformer Primary Status override on Cat ET to turn on the ARD ignition system.

Expected Result:

There are sparks inside the spark indicator.

Results:

There are sparks inside the spark indicator. -
Repair: Turn off the ARD ignition system by disabling the override. Clean the components in the ARD head.
1. Remove the spark plug from the ARD combustion head.
1. Clean the ground probe inside the ARD combustion head by running a 305-2389 Plug Bore Brush through the hole in the ARD combustion head. Run the brush through the hole several times.
1. Inspect the spark plug. Look for the following problems:
  1. Carbon Deposits Clean the spark plug carefully by using a nonmetallic cleaning pad.
  1. 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.
  1. Cracked Ceramic If visible cracking is present. replace the spark plug. Otherwise, install the original plug. Refer to the Specifications manual for the correct torque value.
1. Remove the ARD Flame Temperature Sensor.
1. Clean the ARD Flame Temperature Sensor.
1. Reinstall the ARD Flame Temperature Sensor.
Proceed to Test Step 5.
There are no sparks inside the spark indicator. -
Repair: Turn off the ARD ignition system by disabling the override. Refer to Troubleshooting, "ARD Ignition - Test" for troubleshooting a system without a spark.
STOP

Test Step 5. Perform an ARD Ignition Test

Activate the ARD Ignition Test. The test runs for approximately 5 minutes. Refer to System Operation and Testing and Adjusting, "ARD Ignition - Test".

Results:

The test is successful. - Proceed to Test Step 7.
The test is not successful. - Proceed to Test Step 6.

Test Step 6. Perform the "Engine Air System Verification Test"

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

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

Note: Cat ET 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 7.
The results are not within the acceptable range. -
Repair: Refer to the Troubleshooting, "ARD Combustion Air - Test".
STOP

Test Step 7. Determine the Type of ARD Manifold Fuel Filter Fittings and Replace if Necessary

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.

Show/hide table




Illustration 6	g02720151
Screen element filter fittings (A) 9 mm (0.35 inch) (B) 8 mm (0.30 inch) (9) 323-2205 Filter Connector As (10) 323-2206 Filter Connector As

Show/hide table




Illustration 7	g02719559
Sintered metal element filter fittings (C) 10 mm (0.40 inch) (D) 10 mm (0.40 inch) (11) 353-8397 Connector As (12) 353-8398 Connector As

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 .

Location of Fittings on C13 and C15 Engines.

Show/hide table




Illustration 8	g02720154
The connector filters are located in the manifold for the lines to the ARD head. (13) Location of the connector filters on C15 applications (14) Location of the connector filters on certain C13 applications

Results:

The filters were replaced. - Proceed to Test Step 8.

Test Step 8. Perform the ARD Fuel Nozzle Heater Cycle Override

Perform the ARD fuel nozzle heater cycle by selecting the following menus on Cat ET:
1. "Diagnostics"
1. "Diagnostic Tests"
1. "System Troubleshooting Settings"
1. "ARD Fuel Nozzle Heater Cycle"

Run the ARD fuel nozzle heater cycle for 1 hour.

Results:

Heater cycle is completed - Proceed to Test Step 9.

Test Step 9. Perform an ARD Ignition Test

Activate the ARD Ignition Test. The test runs for approximately 5 minutes. Refer to System Operation and Testing and Adjusting, "ARD Fuel System - Test".

Results:

The test is successful. - Proceed to Test Step 10.
The test is not successful. -
Repair: Contact your local Caterpillar Technical Communicator for further assistance. Attach the data log to the warranty report in SIMSI.
STOP

Test Step 10. Data Log a Stationary Regeneration

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

Data log a stationary regeneration.

Show/hide table

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:

Regeneration completed successfully. A 310 code is logged. -
Repair: Interpret the data log in order to determine if the problem has been resolved. If 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.
STOP
Regeneration did not complete successfully. A 310 code was not logged. -
Repair: Replace the ARD head. Repeat and repeat the last Step. If data log does not show a successful regen, contact your local Caterpillar Technical Communicator for further assistance.
STOP