High Soot Loading on Certain C7.1 Engines {1000, 108D} Caterpillar

Industrial Engine

C7.1 (S/N: 881258-258,272-272,277-277,279-283,290-309,594-603,629-632,635-635,724-733,790-799,835-844,1194-1203,1275-1284,1475-1484,1530-1532,1534-1540,1711-1720,1753-1762,1879-1881,1885-1886,1891-1895,1919-1925,1941-1943,2003-2012,2026-2035,2047-2051,2077-2077,2085-2089,2196-2205,2224-2233,2300-2309,2469-2478,2824-2836,2838-2839,2850-2850,2854-2859,2862-2864,2867-2875,3085-3087,3147-3151,3167-3176,3201-3210,3300-3309,3364-3368,3574-3578,3620-3620,3622-3625,3639-3641,3644-3645,3730-3732,3776-3780,3885-3887,3926-3930,4021-4025,4050-4052,4068-4070,4127-4128,4237-4238,4276-4279,4281-4282,4451-4453,4479-4479,4516-4520,4714-4714,4797-4799,4999-5003,5051-5060,5064-5068,5096-5099,5103-5105,5213-5218,5264-5267,5317-5320,5386-5388,5420-5423)

Introduction

The problem identified below does not have a permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

There have been an increasing number of high-soot loading events leading to machine lock out requiring operator intervention.

Several of the incidents have resulted in no recorded faults or events that can be used to investigate the high soot load event. In a few cases a 3719-16 DPF #1 Soot Loading Percent: High – Moderate Severity (2) has occurred.

Caterpillar is investigating the root cause of these issues. To support the investigation, Caterpillar is requesting that the following steps are completed, documented, and recorded in Service Information Management System (SIMSi) - "CPI Feedback".

Solution

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

1. Use the electronic service tool to download a Product Status Report (PSR) before performing any troubleshooting.

2. Use the electronic service tool to download an "Abnormal Shutdown History Report" before performing any troubleshooting.

3. Review the PSR for active or logged diagnostic codes for high soot loading. Review the percentage soot level using the electronic service tool. If no codes are recorded and the soot percentage is below 105 percent, then record the value for later troubleshooting steps.

4. Check the "Low Idle Speed" configuration setting on the PSR. If the application is a SmartRoc T35 / T40, ensure that the "Low Idle Speed" configuration setting is set to 800rpm. For all other applications, ensure that the "Low Idle Speed" configuration setting is set to 1200rpm.

5. Inspect the J1 connector on the engine Electronic Control Module (ECM). Check that J1:74 is populated with a ground wire back to J1:36. If ground wire is not apparent, install a wire and socket to J1:74 and splice into the digital ground return connection on J1:36. Ensure that the connection is secured with heat shrink.

6. Follow the troubleshooting procedure for an active 3719-16 diagnostic code. Refer to Troubleshooting, Diesel Particulate Filter Collects Excessive Soot.

   Note: During Test Step 2 - "Visually Inspect the Soot Sensor System", refer to M0077352Special Instruction, "Soot Antennae Check for C7.1 Engines"and M0077527Special Instruction, "Low NOx Conversion Event Codes on C7.1 Engines".

   Note: During Test Step 4- "Check for oil in the Exhaust System"- using a borescope camera, take a photograph of the front face of the Diesel Oxidation Catalyst (DOC) in the Clean Emissions Module (CEM).

7. Inspect the Diesel Exhaust Fluid (DEF) injector mounting location for installation of the DEF Injector Coolant Tank (ICT) assembly. Take a photograph of the DEF ICT. Confirm the correct routing of the coolant lines for the DEF ICT.

8. Inspect the DEF Pressure line routing to the DEF injector and confirm that the routing is correct.

9. Inspect the air filters and record current service hours for primary (outer) filter and secondary (inner) filter. If the filter hours are greater than 500 hours, install new filters.

10. Inspect the Exhaust Gas Recirculation (EGR) mixer and the EGR valve assembly. Follow the troubleshooting procedure for an active 2791-7 diagnostic code. Refer to Troubleshooting, Motorized Valve - Test.

11. Install the latest engine software. Refer to Troubleshooting, ECM Software - Install.

12. If the soot load percentage recorded in Step 3is greater than 80 percent, start the engine and wait for the coolant temperature to rise above 60° C (140° F). Use the electronic service tool to perform a "Manual DPF Regeneration". After the "Manual DPF Regeneration" is complete, use the electronic service tool to perform an "Aftertreatment Recovery Procedure".

    Note: Only return the machine to service when the Soot load has been reduced to 60 percent or lower.

    If the soot load percentage recorded in Step 3is less than 80 percent, start the engine and wait for the coolant temperature to rise above 60° C (140° F). Use the electronic service tool to perform an "Aftertreatment Recovery Procedure".

13. After completing the steps above, obtain a PSR using the electronic service tool.

14. If any components have been replaced, record the details and photograph. Retain all removed components in a sealable airtight plastic bag to retain any moisture and retain for 30 days. The components may be requested for return through the Send It Back (SIB) process.

15. In every instance, submit the following information through the SIMSi- "CPI Feedback":

    • TIB media number , M0101605

    • CPI Number 434767

    • Detailed results and any photographs taken during the troubleshooting. Details of any components replaced.

    • Detailed description of the operating conditions when the issue occurred (altitude of job site, ambient temperature, and so on.

    • PSR and History reports from the before and after performing the troubleshooting. Ensure that PDF and XML versions are downloaded, with "Histogram" option selected in the download list.