C15 and C18 – Diesel Particulate Filter Collects Excessive Soot

Use this procedure in order to troubleshoot excessive soot in the Diesel Particulate Filter (DPF). Also use this procedure if one of the following event codes are active. Refer to Troubleshooting, “Event Codes” for information about event codes. For information on the engine monitoring system, refer to Troubleshooting, “Engine Monitoring System”.

Note: Certain systems will display multiple codes for troubleshooting. These “Associated Codes” must be used in order to troubleshoot the system effectively. Refer to Troubleshooting, “General Information” for additional information.

Note: Refer to Troubleshooting, “Cat ET Service Features” for information about service features.

The Engine Control Module (ECM) maintains an estimate of the soot load in the Diesel Particulate Filter (DPF). The estimate is based on the engine operating conditions. If the ECM estimates that the soot load is excessive, the ECM activates the applicable code.

Note: After the regeneration is complete and soot loading is reduced to 0%, the active soot loading code will not become logged or cleared for 5 minutes.

Table 1
Diagnostic Trouble Codes
CDL Code J1939 Codes Code Description
(code descriptions may vary)
Comments
E995 (2) 3719-16 High DPF #1 Soot Loading The estimated soot load is high. The ECM shuts down the engine when this code becomes active for the first time. The engine can be started and operated. Engine power is gradually derated as the soot load increases.
E995 (3) 3719-0 High DPF #1 Soot Loading The estimated soot load is high. Engine operation is limited to 60 second intervals when the Caterpillar Electronic Technician (ET) is not communicating with the ECM.
E991 (3) 3715-31 DPF Active Regeneration Inhibited Due to Permanent System Lockout The estimated soot load is high. The engine may not operate properly. Factory passwords are required in order to clear this code.
E992 (3) 3714-31 DPF Active Regeneration Inhibited Due to Temporary System Lockout The engine has been running for10 minutes after the E995 (3) code was activated.
The Cat ET Manual Diesel Particulate Filter Regeneration must be initiated.
Follow the troubleshooting procedure in order to determine the root cause of the problem.

Note: Engine operation must be kept to a minimum in order to minimize the amount of soot that is created. Follow the troubleshooting procedure in order to minimize the amount of engine operation.

Troubleshooting Procedure

Table 2
Troubleshooting Test Steps Values Results
1. Active Codes and Logged Codes

A. Establish communication between Caterpillar Electronic Technician (ET) and the Electronic Control Module (ECM).

B. Download the “Warranty Report” from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.

C. Look for the following codes:

1. E995 (2) or 3719-16
2. E995 (3) or 3719-0
3. E991 (3) or 3715-31
4. E992 (3) or 3714-31

Codes Result: A E991 (3) or 3715-31 code is present.

Proceed to Test Step 2.

Result: One of the following codes are present:
1. E995 (2) or 3719-16
2. E995 (3) or 3719-0
3. E992 (3) or 3714-31

Proceed to Test Step 3.

2. E991 (3) or 3715-31 code

A. The E991 (3) or 3715-31 code indicates that the engine has continued to run after repeated warnings and engine shutdowns. The DPF must be replaced. Refer to the Disassembly and Assembly, “Diesel Particulate Filter – Remove and Install (Clean Emissions Module)” for the correct procedure.

DPF Result: A E991 (3) or 3715-31 code is present.

Replace the DPF. Refer to the Disassembly and Assembly, “Diesel Particulate Filter – Remove and Install (Clean Emissions Module)” for the correct procedure.

After the DPF has been replaced, clear the E991 (3) or 3715-31 code ( a factory password will be necessary) and proceed to Test Step 3

Table 3
Associated Diagnostic Trouble Codes
E1045 (2)
E1026 (2)
E1025 (2)
E993 (2)
E1156 (1)
E593 (2)
E1239 (1)
E1026 (1)
E1300 (2)
102-18
3473-31
3474-14
3474-31
3609-15
3703-31
3711-31
3750-31
3716-31
Table 4
Troubleshooting Test Steps Values Results
3. Associated Codes

A. Establish communication between Caterpillar Electronic Technician (ET) and the Electronic Control Module (ECM).

B. Check Cat ET for any associated codes that are listed in Table 3.

Associated codes Result: An associated code is active or logged.

Troubleshoot any codes that are present before continuing with this procedure.

Result: An associated code is not active or logged.

Proceed to Test Step 4.

Table 5
Troubleshooting Test Steps Values Results
4. Current Flow through the Heating Element

A. Start the engine.

B. Check the current flow through the heating element. Refer to Systems Operation/Testing and Adjusting, “ARD Nozzle Heater (Current) – Test” for the correct procedure.

Current flow Result: The current flow is acceptable.

Proceed to Test Step 5.

Result: The current flow is not acceptable.

Refer to Troubleshooting, “ARD Nozzle – Test” for the correct procedure.

5. ARD Combustion Air Test

A. Perform the “ARD Air System Service”.

Combustion air test Result: The test results are unacceptable.

Refer to Troubleshooting, “ARD Combustion Air – Test” for information on the test, if necessary. Make the necessary repairs.

Result: The test results are acceptable.

Proceed to Test Step 6.

6. Manual DPF Regeneration

Do not use the cab switch for a stationary regeneration. The service tests provide enhanced diagnostics that are necessary for proper troubleshooting and repair.

A. Start a “Manual DPF Regeneration” in Cat ET.

Manual DPF Regeneration Result: The “Manual DPF Regeneration” was successful.

Return the engine to service.

Result: The “Manual DPF Regeneration” not was successful.

Troubleshoot the diagnostic codes that are present.

Complete the procedure in the order in which the steps are listed.

The procedure corrected the issue. Return the engine to service.

The procedure did not correct the issue.

Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).

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