C13 and C15 On-highway Engines Caterpillar

Use this procedure in order to troubleshoot the listed codes.

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

Illustration 1	g02004574

Illustration 2	g02004636

The fuel system provides the engine and the Aftertreatment Regeneration Device (ARD) with pressurized fuel. This procedure verifies that the fuel system can provide adequate fuel pressure for the cylinder head and for the ARD.

Fuel System Pressures

The typical fuel pressure of the engine at operating temperature can vary.

Use this procedure if the engine starts. If the engine will not start, refer to Troubleshooting, "Engine Cranks But Does Not Start" before you use this procedure.

Fuel Requirements for the ARD

Pilot Fuel (Aftertreatment Fuel Pressure #2). - Pilot fuel is used to start the ARD and pilot fuel is used to run the ARD. The ECM varies the pressure of the fuel according to maps that are in the flash file. The pilot fuel pressure can be viewed on Cat ET. Several factors determine the pilot fuel pressure. One factor is the desired temperature of the exhaust at the intake of the diesel particulate filter (DPF).

Pilot fuel is sufficient for most of the operating conditions of the ARD. However, additional fuel may be required during certain operating conditions. The ECM commands main fuel to flow in order to provide the additional fuel.

Main Fuel (Aftertreatment Fuel Pressure #1) - Main fuel flow is in addition to the pilot fuel flow. The ECM varies the pressure of the fuel according to maps that are in the flash file. The main fuel pressure can be viewed on Cat ET.

Illustration 3	g01620867
Current flow versus total fuel flow for the ARD

Illustration 3 describes the relationship between current flow and total fuel flow for the ARD. Each fuel control valve contains a spring. The spring keeps the valve closed. The spring pressure in the pilot fuel control valve is lower than the spring pressure in the main fuel control valve. The ECM creates a single electrical signal for both of the fuel control valves. The signal causes current to flow through both of the valves. The lower spring pressure in the pilot fuel control valve causes the pilot fuel control valve to open when the flow of current is low. A current flow of approximately 1.2A is required in order to open the pilot fuel control valve. However, the higher spring pressure in the main fuel control valve causes the main fuel control valve to remain closed at 1.2A.

A current flow of approximately 1.3A is required in order for the main fuel control valve to start to open. A current flow of approximately 2.5A is required in order to open the main fuel control valve.

Test Step 1. Determine the Code

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

   Note: The communications adapter must be communicating on both data links in order to perform this procedure. Refer to Troubleshooting, "Electronic Service Tools" for additional information, if necessary.

2. Check for logged codes.

Expected Result:

A 3480-16 or 4077-16 code is present.

Results:

• A 3480-16 or 4077-16 code is present. - Proceed to Test Step 2.

Test Step 2. Inspect the Fuel Enable Valve

Illustration 4	g02006653
Fuel filter base on C13 engines (1) Fuel filter base (2) Fuel enable valve

Illustration 5	g02006673
Fuel filter base on C15 engines (1) Fuel filter base (2) Fuel enable valve

1. Remove the fuel enable valve.

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Illustration 6	g01619614
(G) Correct location for the inner O-ring seal (B) Example of an incorrect location for the inner O-ring seal

2. Inspect the inner O-ring seal. Determine if the inner O-ring seal is in the correct location.

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Illustration 7	g01600013
Outer O-ring seals on the fuel enable valve

3. Verify that all four of the outer O-ring seals are present. Verify that all four of the outer O-ring seals are not damaged.

Results:

• The inner O-ring seal is not in the correct location. The valve has failed. -

  Repair: Replace the fuel enable valve.

  Proceed to Test Step 3 in order to test the operation of the ARD.

• One or more of the outer O-rings seals are damaged or missing. -

  Repair: Replace seals that are damaged or missing. Install the fuel enable valve.

  Proceed to Test Step 3 in order to test the operation of the ARD.

• No problems with the fuel enable valve are observed. - Install the fuel enable valve. Proceed to Test Step 4.

Test Step 3. Perform the ARD Ignition Test in Order to Verify that the Problem is Resolved

Note: The ARD Ignition Test is used to troubleshoot performance problems for the ARD. The test operates the ARD for approximately five minutes. The test determines if the ARD can generate heat. If certain diagnostic trouble codes are active, the test will not start. Record the active codes. Then, clear the active codes in order to run this test.

1. Clear all codes.

2. Start the ARD Ignition Test by selecting the following menus on Cat ET:

   Note: The CRS Ignition Test is the ARD Ignition Test.

   • Diagnostics

   • Diagnostic Tests

   • CRS Ignition Test

Results:

• A 4077-16 or 3480-16 code did not occur as a result of performing the ARD Ignition test. -

  Repair: Return the engine to service.

  STOP

• A 4077-16 or 3480-16 code did occur as a result of performing the ARD Ignition test. - Proceed to Test Step 4.

Test Step 4. Replace the Filter Fittings

Illustration 8	g02006733
(3) Location of the connector filters on C15 applications (4) Location of the connector filters on certain C13 applications

A restriction in the fuel system for the ARD can cause the code. The material causing the restriction will typically move to the connector filters. The material will plug the filters and the filters will need to be replaced. Prior to replacing the filters, the fuel system must be flushed.

Refer to Illustration 8 for the location of the connector filters.

1. Flush the fuel system and replace the filter fittings exactly as instructed in the Special Instruction, REHS3848, "Procedure to Flush the Fuel System for the Aftertreatment Regeneration Device (ARD)".

2. Perform an ARD Ignition Test in order to verify the repair.

3. Start the ARD Ignition Test by selecting the following menus on Cat ET:

   Note: The CRS Ignition Test is the ARD Ignition Test.

   • Diagnostics

   • Diagnostic Tests

   • CRS Ignition Test

Results:

• A 4077-16 or 3480-16 code did not occur as a result of performing the ARD Ignition test. -

  Repair: Return the engine to service.

  STOP

• A 4077-16 code did occur as a result of performing the ARD Ignition test. - Proceed to Test Step 5.

• A 3480-16 code did occur as a result of performing the ARD Ignition test. - Proceed to Test Step 6.

Test Step 5. Replace the Pilot Control Valve

Illustration 9	g02006753
Fuel manifold for the ARD (5) Control valve for the main fuel (6) Control valve for the pilot fuel

1. Replace the pilot control valve.

2. Flush the system.

3. Replace the filter fittings.

4. Perform an ARD ignition test. Start the ARD Ignition Test by selecting the following menus on Cat ET:
   • Diagnostics

   • Diagnostic Tests

   • CRS Ignition Test

Results:

• The ARD ignition test is successful. -

  Repair: Return to Service.

  STOP

• The ARD ignition test was not successful. - Proceed to Test Step 7.

Test Step 6. Replace the Main Control Valve

Illustration 10	g02006755
Fuel manifold for the ARD (5) Control valve for the main fuel (6) Control valve for the pilot fuel

1. Replace the main control valve.

2. Flush the system.

3. Replace the filter fittings.

4. Perform an ARD ignition test. Start the ARD Ignition Test by selecting the following menus on Cat ET:
   • Diagnostics

   • Diagnostic Tests

   • CRS Ignition Test

Results:

• The ARD ignition test is successful. -

  Repair: Return to Service.

  STOP

• The ARD ignition test was not successful. - Proceed to Test Step 7.

Test Step 7. Install a New ARD Head

1. Install a new ARD head. Ensure that all electrical connections are connected. Ensure that all fuel connections are connected.

2. Perform an ARD Ignition Test in order to verify the repair.

3. Start the ARD Ignition Test by selecting the following menus on Cat ET:

   Note: The CRS Ignition Test is the ARD Ignition Test.

   • Diagnostics

   • Diagnostic Tests

   • CRS Ignition Test

Results:

• A 4077-16 or 3480-16 code did not occur as a result of performing the ARD Ignition test. -

  Repair: Return the engine to service.

  STOP

• A 4077-16 or 3480-16 code did occur as a result of performing the ARD Ignition test. -

  Repair: Contact your Technical Communicator.

  STOP