5005655 JOHNSON Service Manual - English

Table 1
Diagnostic Trouble Codes    
CDL Code    J1939 Code    Code Description
(code descriptions may vary)    Comments    
E1092 (1)     412-15     High EGR Temperature     The temperature of the NRS exhaust gas has exceeded the threshold for a set amount of time.    
E1092 (2)     412-16     High EGR Temperature     The temperature of the NRS exhaust gas has exceeded the threshold for a set amount of time.    
Illustration 1 g03779898
Typical left side engine view (1) NRS inlet valve (2) NRS temperature sensor (3) NRS outlet valve
Table 2
Associated Diagnostic Trouble Codes    
E361    
110-15    
110-16    
110-0    
Table 3
Troubleshooting Test Steps    Values    Results    
1. Check for Associated Diagnostic Trouble Codes
A. Establish communication between Cat® Electronic Technician (ET) and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Warranty Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
C. Determine if an associated code is active or logged. Table 2 lists associated diagnostic codes.
   
Associated Diagnostic Code
   
Result: There are associated codes.
Repair: Refer to Troubleshooting, "Diagnostic Trouble Codes" in order to troubleshoot the associated diagnostic code.
Result: A E1092 or 412 code and a E1095 or 2659 code are present.
Proceed to Test Step 3.
Result: There are no associated codes.
Proceed to Test Step 2.
   
Illustration 2 g03779905
NRS cooler (4) Exhaust outlet (5) Vent port (6) Exhaust inlet (7) Coolant inlet (8) Coolant outlet
Table 4
Troubleshooting Test Steps    Values    Results    
2. Perform a "EGR System Test"
A. Reset all active codes and clear all logged codes. Use Cat ET to perform an "EGR System Test" in order to verify that the problem is resolved.
   
Test Completed Successfully
   
Result: The "EGR System Test" did not complete due to a E1092 (2) or 412-16 code.
Repair: Repair the vent line or replace the vent line from the cooler to the shunt tank. Remove the exhaust lines from the inlet and the outlet of the cooler. Inspect the internal passage of the cooler for coolant. If coolant is found, replace the cooler.
Reset all active codes and clear all logged codes. Use Cat ET to perform an "EGR System Test" in order to verify that the problem is resolved.
Return the unit to service.
Result: The "EGR System Test" completed successfully.
Proceed to Test Step 3.
   
Illustration 3 g03779911
Typical right side engine view (9) NRS cooler
Table 5
Troubleshooting Test Steps    Values    Results    
3. Inspect the NRS Cooler
A. Remove the NRS cooler. Refer to Disassembly and Assembly for more information.
B. Perform a leak test on the cooler. Refer to System Operation Testing and Adjusting, "Exhaust Cooler (NRS) - Test" for the proper procedure.
   
Leakage
   
Result: The cooler has internal leakage.
Repair: Replace the cooler. Replace the connection for the bellows at the inlet of the cooler.
On C9.3 engines, the hose must be replaced on the outlet connection of the cooler.
Reset all active codes and clear all logged codes. Use Cat ET to perform an "EGR System Test" in order to verify that the problem is resolved.
Return the unit to service.
Result: The cooler did not have internal leakage.
Repair: Clean the cooler. Refer to Testing and Adjusting, "Exhaust Cooler (NRS) - Clean" for the proper procedure to clean the cooler for the NRS.
    Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).