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Systems Overview
When were
1969 the good old days? Today
0.5
0.4
PM
0.3
EPA ‘91
0.2
0.1 EPA EPA EPA EPA
07/10 ‘04 ‘98 ‘94
0
0 1 2 3 4 5 6 7 8 9 10 11
NOx (g/bhp.hr)
GLOBAL MANPOWER DEVELOPMENT
New Engine Content
Flow
Series Sensor
Turbochargers
Throttle
CGI
Cooler
CGI
ATAAC
Valve
C
T
Diesel
High Particulate
Intake Valve CCV Pressure Filter
Filter
Actuation Injection
System
Flow
Series Sensor
Turbochargers
Throttle
CGI
Cooler
CGI
ATAAC
Valve
C
T
Diesel
High Particulate
Intake Valve CCV Pressure Filter
Filter
Actuation Injection
System
System Components
CGI Line
CGI Line
C15 C7
Consists of:
• ARD (Aftertreatment Regeneration
Device)
• DPF (Diesel Particulate Filter)
• Electronic Controls
2
GLOBAL MANPOWER DEVELOPMENT
Variable Nozzle Turbocharger
AVNT DAVNT
Cam Gear
Bushing Control Valve
Crank Seal
Crankshaft
Turbine Wheel
Pin Vanes
Unison Ring
Unison
Ring
GLOBAL MANPOWER DEVELOPMENT
Unison Ring
Rotating Pin
Inserts Here
On Cam
Hand-off point
LSF ULSF
New ET Codes
2μ
10μ
To CRS
ULSD
System Injectors
6. Do it again!
4. ECM detects
pressure drop
Quill Tube
Oil Here
Quill
HP
Rail
LP
Supply
Outlet Check
Valves
Timing Pin
Remove 8,9
Fuel Enable
Valve
Pilot Fuel
Main Fuel
Air
Compressor Oil
Pressure
Sensor
Fuel returning
from FTP is
230-280 psi
Pilot Fuel
Main Fuel
Main Fuel
Pressure Sensor
Clamps
Pilot Main
Purge Air
Shop Tips
Rubber Grommets
Rubber Grommets
Troubleshooting
• 651,652,653,654,655,656 – 05,06
• Injector #X current Low, High.
• 157 – 03,04
• Fuel Rail Pressure Voltage High, Low
• 1347, 1347 – 05,06
• Fuel Rail Pump #1, #2 Output Current
Low, High
-02
• Cylinder #X Injector A-trim Data Incorrect
• 20% Engine Derate
• Failed injector Solenoid
-07
• Cylinder #X Injector Not Responding
• A-Trim over maximum or minimum adjustment
Test Method:
• Run A-Trim sweep
Service:
• Injector, wiring or ECM
Test Method:
• Run A-Trim sweep
Service:
• Injector, wiring or ECM
Test Purpose:
• Check if pump gear is installed properly
• Check for fuel leaks at low and high rail pressure
• Check if both fuel pump pistons are functional
Test Method:
• All above checks are done by measuring rail pressure
inflections and thresholds during various pumping events
and momentarily cutting out pumping and injection
Service:
• Low Pressure Fuel System, front gear train, troubleshooting for
leaks, HP pump
Test Purpose:
• Check if each injector is delivering fuel
Test Method:
• Estimate pump static leakage, injector dynamic
leakage, injector total fuel delivery: all by measuring
rail pressure by momentarily cutting out pumping or
injection under known conditions
Service:
• Injector or wiring
1. What is a DPF?
Cells Fill Up
Soot Collects
Along the Inlet
Walls
Particulate Matter
or Soot Clean
Exhaust Out
CO2
H2O
NOx
O2
Cordierite
DPF Inlet
Skin
Temperature
Protection
Insulation
Formed Flange
Connections to
Lifting Center Section
Eye
Outer End
Cap
Inner End
Cap Insulation
Pressure
Boss
Sensor Box
Strap
Filter does not
slide out of
center section
Cone feature on
the center section
Cone
Feature on
Center
Section
Rock Guards
75 in/lbs
Outlet Section
Condensate Ring
Insulation
Irreversibility Tab
Insulation
Rain Protection
System on
Verticals
Drain in this area
Air Flow
CGI Line
Purge Pump
Power Connector
Soot
Build Up
Soot Build Up
Soot Build Up
1.94%
.34%
1. 82%
1.55%
.13%
Phase 1
Phase 2
Airflow Unrestricted
Valves Free
of Deposits
Wear
Phase 1 Phase 2
Soot Build Up
Phase 2
DETROIT
• Deep wear grooves – top ring reversal area
• Lack of honing marks throughout ring swept
area
• # 6 intake valves show unusually high levels of
deposits
• Oil rings show severe wear in expanders
• High soot levels, normal result from using EGR
CUMMINS
• Significant Wear Overall
• Significant Higher Top Ring Side Wear
• Cyl. Liners Worn Through Hone Pattern
• 60 MM Wide Below Top Ring Reversal Point
• High Soot Levels, Normal Result from Using
EGR
CATERPILLAR
• Excellent Top Ring Wear for 480K Miles
• Very Light Liner Step @ End of Ring Travel
• Lower Soot Levels = Lower Wear Levels
1,000,000
530,000 490,000
3X 2X
Higher Higher
Cat C15 Cummins DDC S60
Line Haul Line Haul Line Haul
ACERT™ Cooled-EGR Cooled-EGR
355,515 Miles 360,901 Miles 381,100 Miles
High Route
Horizontal
DPF
Resonator
• Noise attenuation
Convection diffuser
• To cool exhaust gas temp
Staining is Acceptable,
Black soot is not
DPF Troubleshooting
Aftertreatment Regeneration 3
• Diesel Particulate Trap #1 Intake Temperature
• Diesel Particulate Trap #1 Outlet Temperature
• Diesel Particulate Trap #2 Intake Temperature
• Diesel Particulate Trap #2 Outlet Temperature
• What is CGI?
• Exhaust Gas from the Clean Side of
the DPF
• Cooled and Recycled through the
Engine
• No more than 15% during normal
operation
CGI
Venturi
Valve CGI
Cooler
ATAAC
CCV Line
Air
Comp
CGI Venturi
Valve CGI
Pre Cooler
Cooler
ATAAC
C
Particulate
ARD
T
T
Filter
OCV
Filter
CRS Purge
Air Pump
NOx
NOx CGI
HH2OO CO
CO2
2 2
PM NOx
NOx
PM HH2OO
NOx PM NOx CO HC
NOx CO
2
CO
CO HC
HC CO2
2
Up to 40% EGR !
Diesel Particulate
PM,
PM,
NOx, CO,
NOx, CO,
EGR Filter / Muffler
HC
HC
PM,
PM,
NOx, CO,
NOx, CO,
PM, NOx, CO, HC
HC
HC NOx ,
H2O, CO2
Oxidation Catalyst Particulate Trap
(“Oxicats”)
CGI Line
CGI Cooler
DPF
From DPF
Air
Flow
Coolant
Coolant
C7 Engine
C15 Engine
Coolant
Line Gas Line
• Temperature Sensor
CGI Gas
Temperature
Sensor
To Differential
Pressure and
Absolute
Pressure
Sensors
(Remotely Mounted)
CGI
Differential
Pressure Air Flow
Sensor
Venturi
Differential
Pressure Sensor
Air Flow
CGI Absolute
Pressure Sensor
• Measures the
difference between the In #1 In #2
two pressures
Measurement
• 3 Wire Active Sensor Diaphragm
• Supply, Return, Signal
In #1 = 10
• Troubleshoots like In #2 = 8
any 3 wire sensor Differential = 2
CGI
Absolute
CGI
Differential
C15
Thermocouples
• 2 Types – single
and dual
• Signal Conditioning
in connector
housing
CGI CGI
Actuator Actuator
Solenoid
Solenoid
Oil Return
Oil Supply
Solenoid
Shaft
Shaft
Electrically
controlled
hydraulic
actuator
LP Turbo
Compressor Inlet
Flow from
CGI Cooler
Flow from
CGI Cooler
Flow from
CGI Cooler
Air Inlet
Temperature
Sensor
Serviceable Components
Control Gp-
Lines Gp-Air CGI (CGI Valve
(CGI Pressure & RHA)
Sensor Lines)
Lines Gp-Air
(CGI Jumper)
Lines Gp-Oil
Cooler Gp-CGI (CGI RHA Oil)
CGI Components
LSF vs ULSF
ULSF LSF
New ET Tests
• Air System Verification Test
• CGI Actuator Sweep Test
CGI Troubleshooting
Air
Comp
Venturi
CGI
CGI
Valve
Cooler
ATAAC
Filter
Variable
Nozzle
Turbo
CCV Line
Air
Comp
Venturi
CGI
CGI
Valve
Cooler
ATAAC
Filter
Variable
Nozzle
Turbo
OCV
Filter
CRS Purge
Air Pump
ir
en A
Sp iti
yg on
ark on
Ign
Ox usti
plu
mb
g
Co
Fuel
Diesel Fuel
Active Regeneration
No
Regeneration Passive Regeneration
Passive Regeneration
Active Regeneration
Active Regeneration
• Occurs at 0 MPH
• Maintain soot during extensive idle periods
• Lower exhaust temp
• 700 RPM, Fan On
• 400° C for 20 minutes every 2 hours
Enhanced Passive
• Occurs at 0 MPH
• DPF lamp must be illuminated
• Must initiate with force switch
• ET commanded manual regen does not require
DPF lamp to be illuminated
Active Regeneration
Mid-Range Warm-Up
• Emissions compliance sooner
• Runs if dpf out is less than 250° C and vehicle speed
is 0 MPH
• Engine RPM remains at low idle due to VNT usage
• Runs until dpf inlet is greater than 450° C (1 second)
or dpf outlet is greater than 325° C for 2 minutes
• Time
• HD - 12 hours (6 hours with sensor fault)
• MR - 5 hours
Pressure
Soot %
Pressure
12 Hrs (5 MR)
Time (hours)
• Coolant Temperature
• Ambient Air Temperature
• Altitude
• Fuel Flow
• DPF Inlet & Outlet Temperature
• Shot Mode
• Engine Speed
• Exhaust Gas Temperature #1 (Turbo Out)
• Exhaust Gas Temperature #3 (Flame Length)
• CGI Flow
• Timing
• Total Exhaust Flow
Operator Interface
HEST Lamp
e L igh
itc e
am e
e
p
Sw evic
d L vic
Sw evic
am
H
h
p
t
sa tion t
La late
h
en
en
ble n De
rat men
era tem
i tc
D
rce on D
tm
tm
mp
u
tur
Fil artic
mp ys
t
o
g e re a
g e re a
g e r tr e a
i
i
ble
t
Te st S
a
a
Re tert
Re ftert
r
r
P
ter
ne
ne
ne
sa
e
Fo
u
el
t
Af
Af
Di
ha
Di
A
M
es
OE
Re
Ex
Di
Kenworth Standard (3) Yes Yes No
Peterbilt Standard (3) Yes Yes No
Freightliner Optional (2) Standard (2) Yes Yes No
International Optional (2) Standard (3)* Yes Yes Optional
Ford No No No No No
GM No Standard (2)* Yes ** No No
HEST
LAMP ON: WHEN TEMP ≥ 840°F (450°C) and SPEED < 5MPH OFF
STOP
ARD disable switch
* Will flash for 30 seconds prior to shutdown ON
OFF FLASHING *
ENGINE Will run 60 seconds each restart
Diagnostic/Event disable
ON FLASHING *
HEST
LAMP ON: WHEN TEMP ≥ 840°F (450°C) and SPEED < 5MPH
STOP
ARD disable switch
* Will flash for 30 seconds prior to shutdown ON
OFF FLASHING *
ENGINE Will run 60 seconds each restart
Diagnostic/Event disable
ON FLASHING *
HEST
LAMP ON: WHEN TEMP ≥ 840°F (450°C) and SPEED < 5MPH
HEST
LAMP ON: WHEN TEMP ≥ 840°F (450°C) and SPEED < 5MPH
STOP
OFF ON SOLID
ENGINE
HEST
LAMP ON: WHEN TEMP ≥ 840°F (450°C) and SPEED < 5MPH
Engine derate
0 100
INCREASING SOOT LOAD
Start
Auto
Stop
! CAUTION OPERATION
• ARD Head
• Spark Plug
• Ignition Coil/cable
• Combustion Air Line
and sensor
• Fuel
Lines/valves/sensors
• ARD Housing
Primary
Secondary
Zone
Zone
Nozzle
Swirler Plate
Pilot
Main
Flame Length
DPF DPF
Outlet Inlet
Turbo Out
ARD Troubleshooting
/Derate/Warning
/Enabled
/Disabled
/2
3714-31
/ Shutdown
• Warning for emergency vehicle ratings only
Shutdown / Derate
• Aftertreatment Regeneration 1
• Total Disable Time
• Secondary Air Differential Pressure
• Fuel Rate
• Fuel Pressure Control Command
Percentage
• Secondary Air Gas Mass Flow
• Aftertreatment Regeneration 2
• Ignition Transformer Primary Status (Off/On)
• Regeneration Status (Active/Inactive)
• Data Link Disable Status (Disabled/Enabled)
• Air Pressure Control Command Percentage
• Disable Switch Status (Off/On)
• Force Switch Status (Off/On)
• Disabled Lamp (Off/On)
• Exhaust System High Temperature Lamp Status
(Off/On)
• Aftertreatment Regeneration Lamp Status (Off/On)
• Aftertreatment Regeneration 3
• Fuel Pressure
• Pilot Fuel Pressure
• Inlet Temperature
• Flame Temperature
• Outlet Temperature
• Diesel Particulate Trap #1 Intake Temperature
• Diesel Particulate Trap #1 Outlet Temperature
• Diesel Particulate Trap #2 Intake Temperature
• Diesel Particulate Trap #2 Outlet Temperature
• Service Procedures
• Manual DPF Regeneration
• Ash Service Test
• Diagnostic Tests
• CRS Ignition Test
• Air Systems Verification Test
Air Pump
40 micron
Filter
Replace when
pump is replaced
Air Pump
14 KPa/2 PSI
Check Valve
Diagnostic Codes
• FMI 00
• FMI 15
• FMI 16
• FMI 17
• FMI 18
• FMI 19
• FMI 20
• FMI 31
a – Total signal input range possible that can be seen by an electronic module
b – Total signal range physically possible as defined by an application
c – Range defined as normal for a given real world measurement
d – Range defined as below normal, MOST SEVERE LEVEL, of what is considered
normal for the given real world measurement
e – Range defined as above normal, MOST SEVERE LEVEL, of what is considered
normal for the given real world measurement
f – Range which is low outside the range of what is considered physically possible for
a given system, indicating a short to a low source has occurred
g – Range which is high outside the range of what is considered physically possible
for a given system, indicating a short to a low source has occurred
Data 01 18 17 15 16 00
Voltage 4 3
Current 5 6
01 15 00
17 16
FMI 17 FMI 16
Data valid but Data valid above
below normal normal operating range
operating range (moderate severe)
(least severe)
18
FMI 18
Data valid but
below normal
operating range
(moderate severe)
Electronics
• A4 Engine ECM
• Data links
• Communication Adapters
• Caterpillar Electronic Technician
J1939
J1708/ATA
• A4 Engine ECM
• Data links
• Communication Adapters
• Caterpillar Electronic Technician
J1939
J1708/ATA
Trans
Engine ATA
ECM Terminal
Block
Gauge
Cluster
Engine ATA
120 Ω
120 Ω ECM Terminal
resistor
resistor Block
Gauge Cab
Backbone Cluster Controller Terminator
2004 ACERT™
• 231-02 J1939 Data Incorrect
• 231-12 J1939 Device Not Responding
• Must guess which device and which device
input is causing the problem
2007
• Diagnostic for each expected ECM
Parameter
• A4 Engine ECM
• Data links
• Communication Adapters
• Caterpillar Electronic Technician
J1939
J1708/ATA
Communication Adapter II
Software Update
Must use
• Caterpillar Communication Adapter II with
serial cable
Can NOT use
• Green Communication Adapter
• Parallel port cable with CAII
• Wireless Communication Adapter
• 3rd party communication adapters
OR
• Application Firmware
Version (Serial IP) 3.1 or
Later
• Comes automatically with
with 2007A v1.1
• Do not need to update CAII
toolkit
Select application
firmware icon
• A4 Engine ECM
• Data links
• Communication Adapters
• Caterpillar Electronic Technician
J1939
J1708/ATA
2007A-V1.1
ATA XXX - XX
J1939 XXXXXX - XX
What is Missing?
Atmospheric
pressure sensor is
now the CGI
absolute pressure
sensor
In #1 In #2
In #1 = 3 Psi
- In # 2 = 2 Psi
Measurement
Differential = 1 Psi Diaphragm
Support Slides
E-mail: media_logistics@cat.com or
Media Logistics (Lotus Notes)