0396085 JOHNSON GEARCASE ASSEMBLY

Table 1
J1939 Code and Description CDL Code and Description Comments
3516-15
Catalyst Reagent Concentration : High - least severe (1) N/A The Diesel Emissions Fluid (DEF) has a high concentration.
3516-17
Catalyst Reagent Concentration : Low - least severe (1) N/A The Diesel Emissions Fluid (DEF) has a low concentration.
4364-17
Aftertreatment #1 SCR Catalyst Conversion Efficiency : Low - least severe (1) E1309 (1)
Low Aftertreatment #1 SCR Catalyst Conversion Efficiency The NOx conversion across the SCR catalyst is lower than expected.
4364-18
Aftertreatment #1 SCR Catalyst Conversion Efficiency : Low - moderate severity (2) E1309 (2)
Low Aftertreatment #1 SCR Catalyst Conversion Efficiency The NOx conversion across the SCR catalyst is lower than expected. Probable Causes
Codes
DEF quality
Check software
DEF pump
DEF pressure line
Urea
SensorsRecommended Actions
Table 2
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Connect Cat® Electronic Technician (ET) to the service tool connector.
B. Look for active codes that are associated with the system for the event code.
Codes
Result: An associated code is active.
Repair: Troubleshoot any associated codes before continuing with this test.
Result: An E1364, E1309, 3516, or 4364 code is active.
Proceed to Test Step 2
2. Check the DEF Quality
A. Using a 431-7087 Tool Gp, measure the Diesel Exhaust Fluid (DEF) quality.
Refer to Testing and Adjusting, "Diesel Exhaust Fluid Quality - Test" for the correct procedure.
25% to 42% DEF Concentration
Result: The DEF quality is NOT within the acceptable range.
Drain the DEF fluid from the tank. Refill the tank with DEF that meets ISO 22241 quality standards.
Proceed to Test Step 3.
Result: The DEF quality is within the acceptable range.
If the problem is not resolved, proceed to Test Step 3.
3. Check the Software Part Number
A. Turn the DC breaker to the ON position.
B. Connect Cat ET.
C. Check the aftertreatment ECM software part number in Cat ET.
Software Part Number
Result: The aftertreatment ECM software part number is 442-7939 SCR System Software 3500 or 440-0164 SCR System Software C175.
This version of software doses 1 L during the "Aftertreatment SCR System Dosing Test".
Proceed to Test Step 4.
Result: The aftertreatment ECM software part number is NOT 442-7939 SCR System Software 3500 or 440-0164 SCR System Software C175.
This version of software doses 2 L during the "Aftertreatment SCR System Dosing Test".
If the problem is not resolved, proceed to Test Step 5.
4. Check the DEF Pump
A. Turn the DC breaker to the OFF position.
B. Remove the DEF line that runs to the DEF injector from the dosing cabinet.
C. Run the DEF line into the container.
D. Turn the AC and DC breaker to the ON position.
E. Connect Cat ET.
F. Perform an "Aftertreatment SCR System Dosing Test" using Cat ET.
Note: While performing this test, the test hose can contain up to an extra 140 mL of fluid. If this fluid drains into the test container, the total volume of DEF will be 1145mL +/- 100 mL.
2 L (+/- 200 mL)
Result: The test returned 1 L +/- 100 mL of DEF.
Proceed to Test Step 7.
Result: The test did not return 1 L +/- 100 mL of DEF.
If the problem is not resolved, proceed to Test Step 6
5. Check the DEF Pump
A. Turn the DC breaker to the OFF position.
B. Remove the DEF line that runs to the DEF injector from the dosing cabinet.
C. Run the DEF line into the container.
D. Turn the AC and DC breaker to the ON position.
E. Connect Cat ET.
F. Perform an "Aftertreatment SCR System Dosing Test" using Cat ET.
Note: While performing this test, the test hose can contain up to an extra 140 mL of fluid. If this fluid drains into the test container, the total volume of DEF will be 2145mL +/- 200 mL.
2 L (+/- 200 mL)
Result: The test returned 2 L +/- 200 mL of DEF.
Proceed to Test Step 7.
Result: The test did not return 2 L +/- 200 mL of DEF.
If the problem is not resolved, proceed to Test Step 6
6. Check the DEF Pressure Line
A. Turn the DC breaker to the OFF position for 1 minute.
B. Visually inspect the lines for leaks or damage.
C. Remove the DEF pressure line between the DEF pump and the DEF injector.
D. Check for ice, urea deposits, or debris in the DEF pressure line.
Restrictions, obstructions, or leaks
Result: There are restrictions or leaks in the lines.
Repair: Remove the restrictions or replace the pressure line.
Proceed to Test Step 7.
Result: There are no restrictions or leaks in the lines.
Proceed to Troubleshooting, "DEF Pressure is Low".
7. Inspect the Exhaust for Urea Deposits
A. Turn the DC breaker to the OFF position for 1 minute.
B. Remove the DEF injector from the exhaust.
C. Inspect the exhaust for signs of urea deposits that block the DEF injector, the mixer, and the SCR catalyst.
Note: Urea deposits in the exhaust are normal and should only be removed if deposits are blocking DEF. Flow from the injector or blocking exhaust flow in the mixer or SCR catalyst.
Urea Deposits
Result: There are urea deposits that are blocking exhaust or DEF flow.
Remove the urea deposits from the exhaust system.
Proceed to Test Step 9.
Result: There are no urea deposits that are blocking exhaust or DEF flow.
If the problem is not resolved, proceed to Test Step 8.
8. Replace the NOx Sensors
A. Turn the DC breaker to the OFF position.
B. Replace the NOx sensors.
NOx Sensors
Repair: The NOx sensors were replaced.
If the problem is not resolved, proceed to Test Step 9.
9. Operate the Engine
A. Turn the AC and DC breaker to the ON position.
B. Start the engine.
C. Connect to Cat® ET and check for active codes.
D. Monitor the "Aftertreatment #1 SCR Inlet Temperature".
E. Operate the engine with the "Aftertreatment #1 SCR Inlet Temperature" above 250° C (482° F) for a minimum of 30 minutes.
Codes
Result: There are no active codes present.
Return the unit to service.
Result: Result: An E1364, E1309, 3516 or 4364 code is active.
Contact your TC.
If 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).