NOx Conversion Is Low
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| Diagnostic Trouble Codes | |
|---|---|
| J1939 Code and Description | Comments |
| 3516-16
Aftertreatment 1 Diesel Exhaust Fluid Concentration : High - moderate severity (2) |
The Diesel Exhaust Fluid (DEF) has a high concentration. |
| 3516-18
Aftertreatment 1 Diesel Exhaust Fluid Concentration : Low - moderate severity (2) |
The Diesel Exhaust Fluid (DEF) has a low concentration. |
| 4364-2
Aftertreatment #1 SCR Catalyst Conversion Efficiency : Erratic, Intermittent, or Incorrect |
The Engine Out and Tailpipe Out NOx Sensors are installed in the incorrect locations. |
| 4364-18
Aftertreatment #1 SCR Catalyst Conversion Efficiency : Low - moderate severity (2) |
The SCR System is not able to reduce NOx in the exhaust system. |
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| Required Service Tools | |
| Part Number | Description |
| 441-0451 | Kit - Test |
Reference: Refer to the appropriate Disassembly and Assembly procedure for removal or installation of components.
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| Troubleshooting Test Steps | Values | Results |
|---|---|---|
1. Determine the Code. A. Establish communication between Cat® Electronic Technician (ET) and the Electronic Control Module (ECM). B. Download the "Warranty Report" from the Aftertreatment ECM before performing any troubleshooting or clearing any diagnostic trouble codes. C. Determine the diagnostic trouble code that is active. |
Diagnostic Code |
Result : A E1410 (2) or 4364-2 code is active or logged. Proceed to Test Step 2. Result : For all codes other than a E1410 (2) or 4364-2, proceed to Test Step 3. |
2. Check the NOx Sensors for Proper Installation. A. Turn the keyswitch to OFF. B. Verify that the sensors are located in the correct position. Note : The "Engine Out NOx" sensor wiring has a black sheath. The "Tailpipe Out NOx" sensor wiring has a gray sheath. C. If the sensors are installed in the wrong positions, install the sensors in the correct positions. Refer to Special Instruction, REHS8151 for the correct handling procedures. D. Perform a "Aftertreatment System Functional Test" using Cat ET. |
NOx Sensors |
Result : The "Aftertreatment System Functional Test" completed successfully. Return the unit to service. Result : The "Aftertreatment System Functional Test" did not complete successfully and other codes were logged. Repair : Troubleshoot the logged codes. |
3. Check the Diesel Exhaust Fluid (DEF) Quality. A. Measure the DEF quality. Refer to Testing and Adjusting, "Diesel Exhaust Fluid Quality - Test" for the correct procedure. |
DEF |
Result : The DEF is not contaminated and the concentration is not within the acceptable range. Repair : Drain the DEF from the tank. Refill the tank with DEF that meets ISO 22241 quality standards. Proceed to Test Step 14. Result: The DEF is not contaminated and the concentration is within the acceptable range. Proceed to Test Step 4. Result : The DEF is contaminated. Repair : Contact the DSN for further information. |
4. Determine the DEF Quality Sensor Installation Status A. Use Cat ET to check the status of the configuration parameter "Aftertreatment #1 DEF Quality Sensor Installation Status". |
Parameter |
Result : "Aftertreatment #1 DEF Quality Sensor Installation Status" is set to "Installed". Proceed to Test Step 5. Result : "Aftertreatment #1 DEF Quality Sensor Installation Status" is set to "Not Installed" or is not listed. Proceed to Test Step 6. |
5. Determine the Diagnostic Code A. Connect Cat ET B. Determine the code that is active. |
Code |
Result : An E1365 (2), 3516–16, E1364 (2), or 3516–18 code is active or logged. Repair : Replace the DEF tank header assembly. Proceed to Test Step 14. Result : An E1309 (2) or 4364–18 code is active or logged. Proceed to Test Step 6. |
6. Inspect All of the DEF Lines for Leaks. A. Turn the keyswitch to ON. Do not start the engine. B. Connect to the "Diesel Exhaust Fluid Controller #1 ECM" in Cat ET. C. Perform the "DEF Dosing System Verification Test" in order to pressurize the system. Refer to Troubleshooting, "Cat ET Service Features" for more information. D. Visually inspect all DEF lines from the tank to the DEF injector. Look for pinched, damaged, or disconnected lines. E. Inspect the lines for leakage. F. Turn the keyswitch to OFF. |
DEF Lines |
Result : The lines are leaking, damaged, pinched, or disconnected. Repair : Make the necessary repairs. Proceed to Test Step 14. Result : The lines are not leaking, damaged, pinched, or disconnected. Proceed to Test Step 7. |
7. Perform an "Aftertreatment NOx Sensor Functional Test". A. Start the engine. B. Connect to the "Engine #1 Aftertreatment Control ECM" using Cat ET. C. Perform an "Aftertreatment NOx Sensor Functional Test". |
Aftertreatment NOx Sensor Functional Test |
Result : The test completed successfully. Proceed to Test Step 8. Result : The test did not complete successfully. A failed NOx sensor was detected. Repair : Replace the failed NOx sensor. Refer to Special Instruction, REHS8151 for the correct handling instructions. Proceed to Test Step 14. |
8. Perform a "DEF Dosing System Accuracy Test". A. Perform a "DEF Dosing System Accuracy Test" using Cat ET. Refer to Testing and Adjusting, "Aftertreatment SCR System Dosing Test" for the correct procedure. |
DEF Dosing System Accuracy Test |
Result : The quantity collected is within specifications. Repair : Re-install the DEF injector. Proceed to Test Step 12. Result: The quantity collected is below specifications. Proceed to Test Step 9. Result : The quantity collected is above specifications. A failed DEF injector has been detected. Repair : Replace the DEF injector. Proceed to Test Step 14. |
9. Check the DEF Pressure Line. A. Turn the keyswitch to OFF. Allow 2 minutes to elapse before proceeding. B. Remove the DEF pressure line between the DEF pump and the DEF injector. C. Inspect the line for obstructions. Flush the line with water or low-pressure air, if necessary. Possible obstructions are ice, DEF deposits, or debris. |
DEF Pressure Line |
Result : An obstruction was found. Repair : Flush the line or replace the line. Proceed to Test Step 11. Result : There are no obstructions. Repair : Reinstall the line. Proceed to Test Step 10. |
10. Replace the DEF injector. A. Turn the keyswitch to OFF. B. Remove the DEF injector. Note : Do not install the injector until Step 11 has been completed. |
DEF Injector |
Result: The DEF injector was connected to the DEF pressure line and the electrical connector. Proceed to Test Step 11. |
11. Perform a "DEF Dosing System Accuracy Test". A. Perform a "DEF Dosing System Accuracy Test" using Cat ET. Refer to Testing and Adjusting, "Aftertreatment SCR System Dosing Test" for the correct procedure. |
DEF Dosing System Accuracy Test |
Result : The quantity collected is within specifications. Repair : Install the DEF injector. Proceed to Test Step 14. Result : The quantity collected is below specifications. Repair : Replace the DEF pump. Install the DEF injector. Proceed to Test Step 14. |
12. Check for Exhaust Leaks. A. Start the engine. B. Check the exhaust system for leaks or damage. C. Check all exhaust connections from the turbo outlet to the tailpipe outlet. D. Check for damage to the exhaust system insulation. |
Exhaust Leaks |
Result : There were no exhaust leaks found. Proceed to Test Step 13. Result : There were exhaust leaks found. Repair : Repair or replace the component that is causing an exhaust leak. Proceed to Test Step 14. |
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| Troubleshooting Test Steps | Values | Results |
|---|---|---|
13. Determine the Fuel Quality A. Take a fuel sample from the fuel tank. Refer to Testing and Adjusting, Fuel Quality - Test. |
Fuel Quality |
Result : The fuel quality is OK. Proceed to Test Step 14. Result : The fuel quality is NOT OK. Repair : Inform the owner of the equipment that Ultra Low Sulfur Diesel fuel must be used in order for the engine to operate properly. Drain the fuel tank and replace the fuel with fuel that meets the specifications for the engine. Proceed to Test Step 14. |
14. Perform an "Aftertreatment System Functional Test". A. Start the engine. B. Connect to the "Engine #1 Aftertreatment Control ECM" using Cat ET. C. Perform an "Aftertreatment System Functional Test". |
Aftertreatment System Functional Test |
Result : The test completed successfully. Return the unit to service. Result : The test did not complete successfully. Proceed to Test Step 15. |
15. Replace both NOx Sensors. A. Turn the keyswitch to OFF. B. Allow time for the exhaust system to cool down. C. Replace both NOx sensors. Refer to Special Instruction, REHS8151 for the correct handling instructions. D. Perform an "Aftertreatment System Functional Test". |
NOx Sensors |
Result : The test completed successfully. Return the unit to service. Result : The test did not complete successfully. Proceed to Test Step 16. |
16. Check the Exhaust Mixer for Damage. A. Turn the keyswitch to OFF. B. Allow the CEM sufficient time to cool down. C. Remove the mixing tube between the DPF outlet and SCR inlet. D. Inspect the exhaust mixer for damage. |
Exhaust Mixer |
Result : The exhaust mixer was not damaged. Proceed to Test Step 17. Result : The exhaust mixer was damaged. Repair : Replace the exhaust mixing tube. Remove any debris from the SCR inlet. Proceed to Test Step 18. |
17. Replace the SCR Catalyst. A. Replace the SCR catalyst. Note: Refer to Special Instruction, REHS8180 for the SCR reset procedure. |
SCR Canister |
Result : The SCR catalyst was replaced. Proceed to Test Step 18. |
18. Perform an "Aftertreatment System Functional Test". A. Start the engine. B. Connect to the "Engine #1 Aftertreatment Control ECM" using Cat ET. C. Perform an "Aftertreatment System Functional Test". |
Aftertreatment System Functional Test |
Result : The test completed successfully. Return the unit to service. |
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