48 ‘Symptom Troubleshooting KENR9146-06 + Wom cylinder bores + Wom valves + Faulty cylinder head gasket + Damaged cylinder head 3. Perform all necessary repairs. 4. Ensure that the repairs have eliminated the fault. 105091000 Alternator Is Noisy Refer to Systems Operation, Testing, and Adjusting for information on possible electrical causes of this. ‘condition. Probable Causes + Alternator drive belt + Alternator mounting bracket + Alternator drive pulley + Alternator bearinas Recommended Actions Alternator Drive Belt Inspect the condition of the alternator drive belt. the alternator drive belt is worn or damaged, check that the drive belt for the alternator and the pulley are correctly aligned. If the alignment is correct, replace the drive belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”. Alternator Mounting Bracket Inspect the alternator mounting bracket for cracks ‘and wear. Repair the mounting bracket or replace the mounting bracket. Ensure that the alternator drive belt and the alternator drive pulley are in alignment, Alternator Drive Pulley Remove the nut for the alternator drive pulley and then inspect the nut and the drive shaft. If no damage is found, install the nut and tighten the nut to the correct torque. Refer to Disassembly and Assembly, “Alternator - Install’ for the correct torque. Alternator Bearings Cheek for excessive play of the shaft in the alternator. Check for wear in the alternator bearings. The alternator is a nonserviceable item. The alternator Tnust be replaced i the bearings are worn. Refer (0 Disassembly and Assembly, ‘Alternator - Remove” and Disassembly and Assembly, “Alternator - Install”. ios00 240 Alternator Problem Probable Causes + Alternator drive belt + Charging circuit + Alternator Recommended Actions Alternator Drive Belt Inspect the condition of the altemator drive belt. If the alternator drive belt is worn or damaged, check that the drive belt for the alternator and the pulley are correctly aligned. If the alignment is correct, replace the drive belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”. Charging Circuit Inspect the battery cables, wiring, and connections in ‘the charging circuit. Clean all connections and tighten all connections. Replace any faulty parts. Alternator Verify that the alternator is operating correctly. Refer to Systems Operation, Testing, and Adjusting, “alternator - Test”. The alternator is not a serviceable item. The alternator must be replaced ifthe alternator is not operating correctly. Refer to Disassembly and Assembly, “Altemator - Remove” and Uisassembly and Assembly, “Alternator - Install’. foross04s ARD Failed to Ignite Note: Before commencing this procedure, ensure that the rework instructions detailed in M0083495,, “aftertreatment Regeneration on 403F-15T, 404F-22, and 404F-22T Engines” has been carried out on the engine. This document has been printed from SPI2. NOT FOR RESALEKENR9146-08 49 ‘Symptom Troubleshooting Use this procedure to troubleshoot the following codes: “Table 59 Diagnostic Trouble Codes for ARO Failed to ignite 31959 Code ‘Code Description Maret ferttealment 1 Failed ignite Not Re-| The ARD temperature has faied to increase as expected, sar Fre koyswvtcn nas boon ON Tor2 seconds. Diognostc codes 168-xx, 3484-0, 3556-8, and 5487 1 are not active Active regeneration is disabled mre [Anerreatmant #1 Faied to lgte Faire [The ARD has failed to inte for a regeneration ede orthe ARD ies to faite during an ARD Ignition Test. Usual, his code is ac- companied by another logged code thal indicates th condition that caused he faire tonite. ineseaion 23 03773166 (1) Air compressor (4) Rood valve (DARD alow plug (2) Compressor intake hose (5) ARD air intake tube (8) Compressor out hose (o)ARD This document has been printed from SPI2. NOT FOR RESALE50 ‘Symptom Troubleshooting KENR9146-06 ‘System Operation ‘The combustion air system routes pressurized air from the outlet of air compressor (1) to the ARD. Reed valve (4) between hose assembly (3) and tube assembly (5) prevents exhaust gas flowing towards the air compressor. The combustion air is mixed with fuel inside ARD combustion chamber (6). The airfuel mixture is ignited by glow plug (7) to increase the temperature of the exhaust gas. The high temperature exhaust gas burns off the soot in the Diesel Particulate Filter (DPF). This process is known ‘as DPI regeneration. ‘The ECM controls the operation of an electronic clutch in the air compressor. The ECM also controls the fuel injectors in the ARD. ‘The ECM controls the ARD glow plug. Whenever the ARD is required to operate, the ECM provides power to the glow plug through a voltage dropper. Ifthe amount of fuel or air that enters the ARD is incorrect or the glow plug does not operate correctty, ‘combustion may not occur. Associated Diagnostic Trouble Codes Use the following procedure to check for associated diagnostic codes: 4. Establish communication between the electronic service tool and the engine ECM. 2. Table 60 lists the diagnostic trouble codes that can be associated with the "3473-7 Aftertreatment #1 Failed to Ignite" code. Determine if any of the ‘codes in Table 60 are present. Table 60 ‘Associated Diagnostic Codes 11999 Code Description ‘Actions Required ro [ECR Main Relay Special Instruction This code fs most key used by shuling down the engine using | ne battery disconnect switch instead of tho Keyswitch fr three eon- secutive shutdowns or using the battery disconnect switch immed lately aftor the kayswtch has boon tuned OFF [An “ARD Feld to Ignite condition ater this code has been active may indicate damage to the ARD fuel injectors. Perm Test Step {Maan Tet Sty 12 uARD ak Supa ls pronase Uy el Ine ARO fue injectors the ARD fue injectors are not injecting fue, replace the ARD fu! Injectors. Refer to Disassembly and Assembly Fuel Injector -Re- move and instal (Aertreatment Regeneration Dowco (ARD) Pr Ime Fue! Injector anc Disassembly and Assembly, Fuel Injector |Romovo ad Install (Ateruoatmont Rogonoraton Dovico (ARD) | Secondary Fue! Incr) Tine “ARD Fatlod to tanto" condition sil extsts, continue wih tis [procedure from the beginning. 404-0 [Aniortroatment #1 lniton : High -most sowee| a) [Refer to ARD laniton Test. This document has been printed (continues) rom SPI2. NOT FOR RESALEKENR9146-08 51 ‘Symptom Troubleshooting fable 60, contd) e043 [arerresiment #1 ignition Voltage Above] Rofor to Ignition Keyswitch Cxcut And Batlory Supply Cut Tost Normal 84-4 FAferresiment #1 ignition Voltage Below | Refer to ARD Ionion Test Normal soe tervoament Fual wypcter #1. Current | Reforto ARD Nozzle Tes. /Above Normal esar-6 FaRerresiment #1 Hyarocarbon Doser #2 | Rofor to ARD Nozzle Test. Current Above Normal ar 0 for #1 cootteeana Percont: igh meat | Rofor to Diesel Pariculata Filer Calais Fxcossive Soot severe (3) sare [Anerreaiment #1 Bumer Unt Combuston [Refer to Engine Temperature Sensor Open or Short Grout Test Ichamber Temperature: Votage Above | (Acive Sensors) Normal Saar fARerreaiment #1 Bumer Unit Combustion — Refer to Engine Temperature Sensor Open or Short Gruit- Test [Chamber Temperature: Volage Below | (Acie Sensors) normal [ares [Aftorsroatment DOC Intake Gas Tomperature: [Rotor to Engine Temporature Sensor Open or Shor Creu Tost [Vottage Above Normal | Active Sensors. aro [Anterreatment DOC Intake Gas Temperature [Refer o Engine Temperature Sensor Open or Shor Creu Test Votago Bolow Nowmal | sctve Sensors) Ifthe associated diagnostic trouble code is present, refer to Troubleshooting, “Diagnostic Trouble Codes" to troubleshoot the associated diagnostic code. ARD Ignition System Visually inspect the components for the ARD ignition system. Check for the following faults: 4. Confirm that the ARD glow plug wring is connected to the correct relay and correct pins on ECM. Refer to the appropriate Electrical ‘Schematic. 2. Confirm that the ARD glow plug wiring is not damaged which can cause a short circuit 3. Confirm that the Altemator is charging. 4. Confirm that the Alternator regulator has not filed and the battery voltage is less than 14.5V. 5. Confirm that the ARD glow plug fuse has not blown. '6. Ensure that the ARD glow plug tightening torque in the ARD head is 23 N-m (17 Ib ft) 7. Ensure that the ARD glow plug nut tightening torque is 1.5N-m (1.1 Ib ft). 8. Use electronic service tool to override the ARD. glow plug and check that the voltage drop over the dropping resistoris 2V. 9. Use electronic service tool to override the ARD_ low plug and check that the glow plug relay is ‘operating correctly. 410. Use electronic service tool to override the ARD. ‘glow plug and check that the glow plug heats up (should visibly glow), ARD Air Supply Visually inspect the components for the ARD Air supply. Check for the following faults: 4. Confirm that the ARD Air pump wiring is connected to the correct relay and correct pins on ECM. Refer to the appropriate Electrical Schematic. 2. Confirm that the ARD Air pump fuse has not blown. 3. Confirm that there are no kinks in the airlines to restrict the flow. 4. Confirm that the reed valve is not blocked and can move freely. 5. Confirm that the air pump belt is tensioned correctly: New belt = 310 N (70 Ib), Used belt = 220.N (49.5 Ib). Ifthe air pump belt is damaged or ‘worn, replace the belt. 6. Confirm that the ARD air pump wiring is not damaged 7. Check if the air fiter is blocked. Change fiter if maintenance schedule has passed. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” This document has been printed from SPI2. NOT FOR RESALE52 ‘Symptom Troubleshooting KENR9146-06 8. Use electronic service tool to override the ARD Air pump and check that the ARD Air Pump relay is. ‘operating correctly. 9. Use electronic service tool to override the ARD Air pump and check that the ARD Air Pump clutch activates. ARD Fuel Supply Visually inspect the components for the ARD Fuel supply. Cheeks for the following faults: 4. Confirm that the ARD injector wiring is connected to the correct relay and correct pins on ECM, Refer to the appropriate Electrical Schematic. 2. Confirm that the engine wiring harness is connected to the correct ARD injector (Injector 1 = brown connector, Injector 2 = gray connector). 3. Confirm that the ARD injector fuse has not blown, 4. Confirm if the electri lit pump is damaged. 5. Confirm that there are no kinks in the fuel lines to restrict the flow. 6. Check ifthe primary fuel fiteris blocked. Change filter if maintenance schedule has passed. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” 7. Check if the secondary fuel fiter is blocked, ‘Change filter if maintenance schedule has passed. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule". 8. Confirm that there is no air in the fuel ine. Allow the lift pump to circulate fuel around the engine at Key on before cranking the engine. 9. Confirm that the battery voltage is greater than 18V during a DPF regeneration. 10. Use electronic service tool to override the ARD injector and check that the ARD injector relay is ‘operating correctly. 11. Use electronic service tool to override the ARD injector 1 and check that ARD injector 1 is injecting fuel. 12. Use electronic service tool to override the ARD injector 2 and check that ARD injector 2s injecting fuel. Battery Voltage 4. Confirm that the battery voltage is greater than 13V during a DPF regeneration with all the engine auxiliary components activated. Aftertreatment Temperature Sensors (3473-12 only) Visually inspect the Aftertreatment Temperature ‘Sensors component. 41. Confirm that the Aftertreatment temperature sensors are located in the correct position: DOC In (gray), DPF In (black) and DPF Out (whi connector). ‘oror4s61 ARD Is Disabled Use this procedure in order to troubleshoot a failed Diesel Particulate Filter (DPF) regeneration. Also, use this procedure if one of the following diagnostic ‘trouble codes are active. This document has been printed from SPI2. NOT FOR RESALE58 ‘Symptom Troubleshooting KENR9146-06 Valve Lash 1. Refer to Troubleshooting, “Valve Lash Is Excessive". 2. Ifthe fault has not been eliminated, proceed to “Low Compression (Cylinder Pressure)”. Low Compression (Cylinder Pressure) 1. Perform a compression test. Refer to Systems ‘Operation, Testing, and Adjusting, “Compression - Test” 2. flow compression is noted on any cylinders, investigate the cause and rectify any faults, Possible causes of low compression are shown in the following list: + Loose glow plugs + Faulty piston + Faulty piston rings. + Wom cylinder bores + Worn valves + Faulty cylinder head gasket + Damaged eylinder head 3. Perform all necessary repairs, 4, Ensure that the repairs have eliminated the faults. 5. Ifno faults are detected, proceed to ‘Pistons’. Pistons 1. Inspect the pistons for damage and wear. Replace any damaged parts. 2. Ifthe noise is still present, contact Perkins Global Technical Support. Diesel Particulate Filter Collects Excessive Soot ‘When the Aftertreatment Regeneration Device (ARD) requires troubleshooting, there will be multiple codes to assist the troubleshooting process. A “Soot Loading-High” code is not the cause of the fault. Troubleshoot any associated codes to clear the fault that has caused the “Soot Loading-High’ code, Troubleshooting the associated codes may lead to a code that is the root cause of the fault. Engine operation must be kept to a minimum to minimize the amount of soot that is created. Follow the troubleshooting procedure to minimize the amount of engine operation. ‘The Electronic Control Module (ECM) maintains an estimate of the soot load in the DPF. The estimate is based on the operating conditions of the engine. Ir the ECM estimates that the soot load is excessive, the ECM aetivates the applicable code. Note: After a regeneration and soot loading is. reduced to 0%, the active soot loading code will not be logged or cleared for 5 minutes. This document has been printed from SPI2. NOT FOR RESALEKENR9146-08 59 ‘Symptom Troubleshooting “Table 03 Diagnostic Trouble Code for Excessive Soot Load J1939 Gode and Description Information that Relates to the Code 3719-16 High Diesel Paricu- |The estimated soot oad s igh. Engine spood and lorque are dated. The waming lamp wil ash and the late Fite #1 Soot Leading - DPF lamp wil be on Lovel3 Te keyswitch must be turned to the OF poston to complete the active regeneration, '3710-0 High Diesel Parteulato [he estimated soot ad ishigh- The engine wil sop. Active regeneration sinhibted. The warring Ip will Fiter #1 Soot Loading - Leve3| ish, the shutdown lamp wil be on, and! the DPF lamp vl be on ie asym sate ty Uns OF poston. The electron servis tool must be used to perform an ac- [ve regeneration Follow the Woubleshootng procedure to determine the root cause ofthe problem, Troubleshooting Procedure (able 64, conta) 4. Connect the electronic service too! to the ‘Associated Codes diagnostic connector. Check for diagnostic codes 'J1939 Suspect Parameter | Failure Mode Identifier that relate to the Clean Emissions Module (CEM). ‘Number (SPN) (FM Refer to Table 64. Troubleshoot any codes that are present before continuing with this procedure. Tablo 64 ‘Associated Codes. ‘31939 Suspect Parameter ‘Number (SPN) aw 110 168 Use the electronic service tool to perform a service regeneration after the successful completion of the diagnostic procedures. 108 3241 a. Ifthere are no associated codes, proceed to Test Step 2. som 3241 242 3242 242 3473 ara ‘404 3556 ana ana This document has been printed from SPI2. NOT FOR RESALE60 ‘Symptom Troubleshooting KENR9146-06 Taran ‘Typical view of the CEM (1) DPF outet pressure sensor (2) DPF outlet pressure sensor {@)ARD combustion head (@) Diesel Oxdaton Catalyst (D0C) (5)DOC intake tamperature sensor (0) DPF intake temperature sensor (Dies! Harteulate itor (DP) (0) DPF outet temperature sensor 2. Use the following procedure to test the ARD air system: 1a. Use the electronic service tool to perform the ARD Air System Service Test. b. Ifthe ARD Air System Service Testis not successful, troubleshoot the ARD air supply ‘and then proceed to Test Step 3. Ifthe ARD Air System Service Test is successful, proceed to Test Step 3 3. Perform this Test Step if all the following conditions, are true: + The “DPF Dieable” ewitoh wae notin the DISABLED position. + The ARD fuel injectors are operating correctly. + The results of the “ARD Combustion Air- Test” are acceptable. Proceed to Test Step 4 if @ fault has been discovered and the fault has been rectified. ‘a. Remove the outlet section from the DPF and then remove the DPF. Inspect inside the inlet ‘section and the front face of the DPF. Look for oll and for excessive soot. ‘The presence of a small amount of soot is a normal condition. If the amount of soot is considered to be excessive, contact Perkins Global Technical Support. Continue with this procedure after guidance has been received from Global Technical Support. Ifoil is found, inspect the outlet of the turbocharger. If lis found, contact Perkins Global Technical Support. Continue with this procedure after guidance has been received from Global Technical Support. Clean the oil from inside the inlet section of the DPF and the front face of the DPF. Assemble the DPF. Run the engine at 1400 rpm for 15 minutes. Then, proceed to Test Step 4. Note: Do not use the cab switch to regenerate the DPF. The service tests provide enhanced diagnostics that are necessary for proper troubleshooting and repair. Note: During the following step, make sure that the procedure has completed and the diagnostic code has cleared before the electronic service tool is. disconnected. Although the soot load may show "0%" an ECM leam process must complete before the diagnostic code is reset. The procedure may take more than 30 minutes to complete. 4, Perform a service regeneration by selecting the following menus on the electronic service tool: + “Service Procedures” + ‘Manual Diesel Particulate Filter completion of the procedure. ‘ono1ss03 Diesel Particulate Filter Has Changed Regencration Interval Associated Diagnostic Trouble Codes Use the following procedure to check for associated diagnostic codes: This document has been printed from SPI2. NOT FOR RESALE