System Operation Description:
Use this procedure to troubleshoot the following code.
Note: Refer to Troubleshooting, “Cat ET Service Features” for information about service features.
Note: Some of the following codes may not be applicable for certain applications.
| Diagnostic Trouble Codes | |||
| CDL Code | J1939 Code | Code Description (code descriptions may vary) |
Comments |
| 2465-5 | 3484-5 | Aftertreatment #1 Ignition Transformer Primary : Current Below Normal | The current flow through the primary ignition circuit is below the threshold. A snapshot is triggered. If a regeneration is in progress, the ARD completes the regeneration. |
| 2465-6 | 3484-6 | Aftertreatment #1 Ignition Transformer Primary : Current Above Normal | The current flow through the primary ignition circuit is above the threshold. A snapshot is triggered. If a regeneration is in progress, the ARD completes the regeneration. |
| 3180-5 | 4265-5 | Aftertreatment #1 Ignition Transformer Secondary : Current Below Normal | The ARD has attempted to ignite three times. All of the attempts were unsuccessful. The ECM has detected a problem with the current flow through the secondary circuit. The primary circuit is OK. The spark plug is fouled. or There is a problem with the ignition wire between the ignition coil and the spark plug. These problems usually occur because the ignition wire has been damaged by excessive heat or improper routing. or The ignition coil has a problem. |
| Follow the troubleshooting procedure in order to identify the root cause of the problem. | |||
| Required Tooling for the Procedure |
| 373-4609 Spark Tester |
| Troubleshooting Test Steps | Values | Results |
|---|---|---|
| 1. Determine the Diagnostic CodeA. Connect Caterpillar Electronic Technician (ET) to the service tool connector.
B.Use the “Aftertreatment #1 Ignition Transformer Primary Override” on Cat ET to turn on the ARD ignition system. The ARD ignition system must operate for 20 seconds in order for a diagnostic trouble code to become active. securely. C. Determine the diagnostic code that is present. |
Diagnostic code | Result: A 2465-5, 2465-6, 3484-5 or 3484-6 code is present.Proceed to Test Step 5.
Result: A 3180-5 or 4265-5 code is present or a diagnostic code is not present. Proceed to Test Step 2. |
| 2. Inspect the Ignition WireA. Visually inspect the ignition wire between the ignition coil and the ARD combustion head. Look for the following problems:
1. Loose connections or damaged connectors 2. Moisture on the connectors or the ignition wire 3. Damage to the ignition wire that is caused by excessive heat 4. Damage to the ignition wire that is caused by chafing 5. Improper routing of the ignition wire 6. Damaged insulation on the ignition wire B. Push the boot on each end of the ignition wire. This tests whether the clip inside the boot is connected to the spark plug and to the ignition coil. There should be a “click” when you push the boot onto either part. If you felt a “click”, the clip inside the boot was not previously connected. |
Damaged wire | Result: The ignition wire is not damaged.Proceed to Test Step 3.
Result: The ignition wire is damaged. Replace the ignition wire. Proceed to Test Step 7. |
Illustration 1 g02388518
(1) 373-4609 Spark Tester
| Troubleshooting Test Steps | Values | Results |
|---|---|---|
| 3. Check for Spark at the Coil Output, Using the Spark IndicatorA. Assemble the 373-4609 Spark Tester as shown in Illustration 1. Ensure that the alligator clip is secured to a good ground source.B. Install the spark indicator as shown in illustration 2. C. Use the “Aftertreatment #1 Ignition Transformer Primary Override” on Cat ET to turn ON the ARD ignition system. Check for spark in the spark indicator. |
Spark | Result: Spark is present in the indicator.Proceed to Test Step 4.
Result: Spark is not present in the indicator. Replace the ignition coil. Inspect the connector terminals. If terminal damage/erosion is found, repair the ground from the coil housing to the chassis. Also, inspect the ground wire from the coil to the ARD head. Proceed to Test Step 7. |
Table 5
Troubleshooting Test Steps Values Results
4. Check for Spark to the Spark Plug
A. Assemble the 373-4609 Spark Tester as shown in Illustration 3.
B. Install the spark plug indicator between the spark plug and the end of the spark plug wire.
C. Use the “Aftertreatment #1 Ignition Transformer Primary Override” on Cat ET to turn ON the ARD ignition system. Check for spark in the spark indicator.
Spark
Result: Spark is present in the indicator.
Replace the spark plug. Proceed to Test Step 7.
Result: Spark is not present in the indicator.
Replace the ignition wire. Proceed to Test Step 7.
Illustration 4 g01395281
Information for the ignition circuit.
| Troubleshooting Test Steps | Values | Results |
|---|---|---|
| 5.Check for Voltage at the Ignition CoilA. Disconnect the connector from the ignition coil. Not all connectors may be shown in the illustration above, refer to the electrical schematic. B. Turn the keyswitch to the “ON” position. C. Establish communication between Cat ET and the ECM . Refer to Troubleshooting, “Electronic Service Tools”, if necessary. D. Use the Aftertreatment #1 Ignition Transformer Primary Override in Cat ET to turn ON the ARD ignition system. Measure the voltage between terminal 1 and terminal 3 on the Clean Emissions Module (CEM) harness connector for the ignition coil. E. Turn off the ARD ignition system by disabling the override. |
Greater than 8 VDC | Result: The voltage between terminal 1 and terminal 3 is greater than 8 VDC.Proceed to Test Step 6.
Result: The voltage between terminal 1 and terminal 3 is less than 8 VDC. The problem is in the wiring between the ECM and the ignition coil connector. Repair the wiring or replace the wiring. Proceed to Test Step 7. |
| Troubleshooting Test Steps | Values | Results |
|---|---|---|
| 6. Check the Ground for the Ignition CoilA. Disconnect the connector from the ignition coil.
B.Turn the keyswitch to the ON position. C. Establish communication between Cat ET and the ECM . Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Use the Aftertreatment #1 Ignition Transformer Primary Override in Cat ET to turn ON the ARD ignition system. Measure the voltage between terminal 1 and terminal 2 on the Clean Emissions Module (CEM) harness connector for the ignition coil. Turn off the ARD ignition system by disabling the override. |
Greater than 8 VDC | Result: The voltage between terminal 1 and terminal 2 is greater than 8 VDC.Replace the ignition coil. Proceed to Test Step 7.
Result: The voltage between terminal 1 and terminal 2 is less than 8 VDC. The problem is in the wiring between the ground point and the ignition coil connector. Repair the wiring or replace the wiring. Proceed to Test Step 7. |
| 7. Check the ARD for Proper OperationA. Perform the ARD Ignition Test using Cat ET. The test runs for approximately 5 minutes.
The ARD Ignition Test cannot be performed if the DPF soot loading is above 80%. When the DPF soot loading is above 80%, the Manual DPF Regeneration must be performed using Cat ET. |
Successful Test | Result: The test is successful.Return the unit to service.
Result: The test is not successful and additional codes are logged. Troubleshoot the codes. Refer to Troubleshooting for the correct procedure. |
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