C15 and C18 – Exhaust Balance Valve – Test

System Operation Description:

Use this procedure to troubleshoot the following codes:

Note: Component locations outlined in this procedure may not represent all applications. Refer to the system operations manual of the machine or engine you are working on for correct component locations.

Note: Some of the following codes may not be applicable for certain applications.

Table 1
Diagnostic Codes
CDL Code J1939 Code Code Description
(code descriptions may vary)
Comments
E1123 (1) 5276-7 Engine Exhaust Manifold Bank #1 Flow Balance Valve Not Responding to Command The engine ECM determines when conditions are adequate to open the exhaust balance valve. Also, the engine ECM determines when conditions are adequate to close the exhaust balance valve. The engine ECM monitors the NRS gas flow to determine if the exhaust balance valve reacted as commanded. If the NRS gas flow does not match the desired rate, the fault is logged.
E1123 (2) 5276-7 Engine Exhaust Manifold Bank #1 Flow Balance Valve Not Responding to Command The engine ECM determines when conditions are adequate to open the exhaust balance valve. Also, the engine ECM determines when conditions are adequate to close the exhaust balance valve. The engine ECM monitors the NRS gas flow to determine if the exhaust balance valve reacted as commanded. If the NRS gas flow does not match the desired rate, the fault is logged. Engine power is derated.
Follow the troubleshooting procedure in order to identify the root cause of the problem.
Table 2
Required Tooling For C9.3 Applications
Quantity Part Number
1 215-2592 Wastegate Kit
1 5P-8869 9/16″-18 JIC to 1/4″-18 NPTF
1 006-6586 1/4″-18 NPTF to hose barb
Table 3
Required Tooling For C13, C15 and C18 Applications
Quantity Part Number
1 215-2592 Wastegate Kit
1 061-7921 7/16″-20 JIC to 1/4″ NPTF
1 006-6586 1/4″-18 NPTF to hose barb
Table 4
Troubleshooting Test Steps Values Results
1. Check for Diagnostic Trouble CodesA. Establish communication between Caterpillar Electronic Technician (ET) and the Electronic Control Module (ECM) . Refer to Troubleshooting, “Electronic Service Tools”, if necessary.

B. Determine if a code is active or logged.

Diagnostic Trouble code Result: An E1123 or 5276-7 code is active or logged.Proceed to Test Step 2.


Illustration 1 g02032893
(1) Connection points to check

Table 5
Troubleshooting Test Steps Values Results
2. Inspect the Air Lines from the Exhaust Balance Valve Solenoid to the Exhaust Balance Valve ActuatorInspection of the air lines is difficult in some applications. Test Step 6 will provide further testing procedures.
A. Inspect the air lines from the outlet of the exhaust balance valve solenoid to the inlet of the exhaust balance valve actuator. Inspect the lines for any signs of leakage.
Damaged air line Result: A line is damaged.Repair the line or replace the line. Return the unit to service.

Result: A line is not damaged.

Proceed to Test Step 3.


Illustration 2 g02032979
(2) Linkage to the exhaust balance valve

(3) Connection point from the exhaust balance valve to the linkage, soot build -up at this linkage is normal

Table 6
Troubleshooting Test Steps Values Results
3. Inspect the Linkage to the Exhaust Balance ValveA. Inspect the linkage to the exhaust balance valve from the canister to the housing. Also, inspect the connection point from the linkage to the valve. Inspect the linkage for the following issues:
1. Bending
2. Breakage
Damaged or broken linkage Result: The linkage is damaged.Replace the turbocharger. Return the unit to service.

Result: A linkage is not damaged.

Proceed to Test Step 4.

Illustration 3 g02337917
(4) Pressure regulator on the 215-2592 Wastegate Kit

(5) Gate valve # 1 on the 215-2592 Wastegate Kit

(6) Pressure gauge on the 215-2592 Wastegate Kit

(7) Hose from the mixer to the exhaust balance valve solenoid

(8) Exhaust balance valve solenoid

(9) Exhaust balance valve

(10) Gate valve # 2 on the 215-2592 Wastegate Kit


Illustration 4 g02402325
(7) Hose

Only disconnect the hose from the mixer, do not disconnect the hose from the balance valve solenoid.


Illustration 5 g02402320
(5) Gate valve #1

(10) Gate valve #2


Illustration 6 g02338036
(11) Fitting for the line to the exhaust balance valve

 

Table 7
Troubleshooting Test Steps Values Results
4. Test the Exhaust Balance Valve Solenoid to Make Sure that the Valve Is Not Stuck in the Closed PositionA. Disconnect hose (7) from the mixer. Refer to Illustration 4.

B. Connect the 215-2592 Wastegate Kit and necessary adapters between hose (7) and the mixer. The other end of hose (7) must stay connected to the inlet of the balance valve solenoid.

C. Turn the keyswitch to the OFF position.

Only apply 138 kPa (20 psi) air pressure to the exhaust balance valve.

D. With gate valve (5) in the open position, regulate the supply air pressure to
138 kPa (20 psi). Make sure gate valve (10) is closed. Once the pressure is stable, close gate valve (5) .

E. Loosen fitting (11) for the line from the exhaust balance valve solenoid to the exhaust balance valve.

Valve stuck closed Result: Air leaked out of the line from the exhaust balance valve solenoid after the fitting was loosened.The solenoid is not stuck closed. Proceed to Test Step 5.

Result: Air did not leak out of the line from the exhaust balance valve solenoid after the fitting was loosened.

The exhaust balance valve solenoid is not operating properly. Replace the exhaust balance valve solenoid. Return the unit to service.

5. Test the Exhaust Balance Valve Solenoid to Make Sure that the Valve Is Not Stuck in the Open PositionA. Relieve any residual pressure in the system by using gate valve (10) on the wastegate test kit. Once the pressure is relieved, close the valve.

Only apply
138 kPa (20 psi) air pressure to the exhaust balance valve.

B. With the gate valve (5) in the open position, regulate the supply air pressure to
138 kPa (20 psi). Make sure gate valve (10) is closed. Once the pressure is stable, close gate valve (5) .

C. Turn the keyswitch to the ON position.

D. In Cat ET, navigate to the”Engine Exhaust Manifold Bank #1 Flow Balance Valve Solenoid Override” “Override Parameters” menu under the diagnostic tab. Override the exhaust balance valve to ON.

E. Loosen the line to the balance valve from the exhaust balance valve solenoid.

Valve stuck open Result: Air leaked out of the line from the exhaust balance valve solenoid after the line was loosened.The exhaust balance valve solenoid is not operating properly. Replace the exhaust balance valve solenoid. Return the unit to service.

Result: Air did not leak out of the line from the exhaust balance valve solenoid after the line was loosened.

The solenoid is operating properly, Proceed to Test Step 6.

6. Pressure Test the System for LeaksA. Relieve any residual pressure in the system by using gate valve (10) on the wastegate test kit. Once the pressure is relieved, close the valve.

Only apply
138 kPa (20 psi) air pressure to the exhaust balance valve.

B. With the gate valve (5) in the open position, regulate the supply air pressure to
138 kPa (20 psi). Make sure gate valve (10) is closed. Once the pressure is stable, close gate valve (5) .

C. Turn the keyswitch On in order to activate the exhaust balance valve solenoid.

Air should now flow between gate valve (5) and the exhaust balance valve.

System leaks Result: The pressure on the gauge maintains approximately
138 kPa (20 psi).There are no leaks in the system. Proceed to Test Step 7.

Result: The pressure on the gauge does not maintain
138 kPa (20 psi).

There is a leak in the system. Check all lines and connections and repair the leak. Return the unit to service.

7. Check the Spring for the Exhaust Balance ValveA. Remove all air pressure from the exhaust balance valve actuator.

B. Try to move the linkage rod for the exhaust balance valve by hand.

Broken spring Result: The linkage will move by hand.Replace the exhaust balance valve actuator. Return the unit to service.

Result: The linkage would not move by hand.

Proceed to Test Step 8.


Illustration 7 g02393201
(12) Cover for the exhaust balance valve chamber

 

Table 8
Troubleshooting Test Steps Values Results
8. Inspect the Exhaust Balance Valve

A. Relieve all pressure from the exhaust balance valve system.

B. Remove the cover from the exhaust balance valve chamber.

C. Ensure that the exhaust balance valve is not broken.

Damaged or broken valve Result: The exhaust balance valve is broken.

Replace the turbocharger. Return the unit to service.

Test Step 1.

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

Results:

  • The procedure corrected the issue. – STOP
  • The procedure did not correct the issue. –Repair: Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).

    STOP

Posted in C18

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