99011-89J08-03A Suzuki MANUAL, OWNER'S

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
There have been several field reports of high soot loading on Tier 4 Interim C4.4 or C6.6 engines. The regeneration system on the Tier 4 Interim C4.4 or C6.6 engine is designed to manage the soot loading, automatically. The regeneration system should require no intervention by the operator or service technician. If the engine event code E995 High DPF #1 Soot Loading is logged, this code indicates a system malfunction and should be diagnosed. Contact your local Technical Communicator for assistance in diagnosis and to feedback information found to Caterpillar.Tier 4 Interim C4.4 or C6.6 engine DPF regeneration can occur under the following conditions:
During normal machine operation (Stationary or in Motion)
At all desired engine speeds (Low Idle and High Idle)
During extended low idle conditions
In all ambient temperature conditions
During both high engine loading and low engine loading operationsSome have been lead to conclude that machines fitted with these engines need to work hard in order for the passive regeneration system to work correctly to avoid engine event code E995 High DPF #1 Soot Loading. This conclusion is incorrect and should not be perpetuated within the dealer and service community.Solution
The list of the six root causes found to date is in order of likelihood and ease to fix. If these interim actions do not resolve the high soot load event, the root cause may be new. Data will have to be taken on machine using a SuperComm 2. SuperComm 2 plugs into the diagnostic connector in the cab and wirelessly sends data back to the CPI team without customer interruption. The best candidates for using an SC2 are machines in areas where theft/vandalism is not a concern and a Verizon wireless signal is decent. Indicate the results of the steps taken on the DSN ticket.A) Reseed floor fix via flash file
The Soot signal is not able to complete a reseed (sanity check) within 50 to 150 hours of the last reseed. Fixes in place:
Record soot load in ET.
Warm up the engine/machine for 20 minutes.
Record soot load in ET.
Flash engine with new file.
Warm up the engine/machine for 20 minutes.
Record soot load in ET. If the flash file addressed the root cause, the soot load would reduce by more than 10% from Steps 3 to 6. If the soot load remains high, the root cause has not been addressed.B) Exhaust constraint
Constraints inhibit passive regeneration of soot.
Remove the exhaust cap.
Record soot load in ET.
If soot load is greater than 90%, leave machine idling. Without ever shutting down the engine, check the soot load in ET every 30 minutes until soot load reaches 80%. Return machine to the customer. Advise the customer to check the soot load upon next visit or in 200 hours.
If soot load is less than 90%, return machine to the customer. Advise the customer to check the soot load upon next visit or in 200 hours.C) Exhaust leak
Exhaust leaks impair passive regeneration.
Check for any exhaust leaks prior to the DPF and repair.
Record soot load in ET.
If soot load is greater than 90%, leave machine idling. Without ever shutting down the engine, check the soot load in ET every 30 minutes until soot load reaches 80%. Return machine to the customer. Advise the customer to check the soot load upon next visit or in 200 hours.
If soot load is less than 90%, return machine to the customer. Advise the customer to check the soot load upon next visit or in 200 hours.D) Soot sensor coaxial cable bend radius
If the minimum bend radius (51 mm (2.0 inch)) of the coaxial cable is violated, the impedance within the coaxial cable is compromised and the soot system will interpret the signal incorrectly.
Warm machine for 20 minutes.
Record soot load in ET.
Let exhaust components cool. In the aftertreatment compartment, inspect the bend radius of both coaxial cables.
Take pictures of anything suspect and attach to DSN.
Replace any suspect components.
Warm machine for 20 minutes.
Record soot load in ET. If the soot load has reduced by more than 10%, return the machine to the customer. If the soot load has not reduced, then the coax cable bend radius was not the root cause.E) Mating components of soot antenna
If the mating components of the coax cable and the soot antenna are cross threaded or not torqued correctly (1.2 N m (0.90 lb ft)), the impedance of the signal is compromised and the soot system will interpret the signal incorrectly.
Warm machine for 20 minutes.
Record soot load in ET.
Let exhaust components cool. In the aftertreatment compartment, inspect the mating components of the coax cable and the soot antenna for damage and cross-threading.
Take pictures of anything suspect and attach to DSN.
Replace any suspect components.
Warm machine for 20 minutes.
Record soot load in ET. If the soot load has reduced by more than 10%, return the machine to the customer. If the soot load has not reduced, then the mating components were not the root cause.F) Engine Start/Stops
If the product status report shows an average of more than two starts and stops per hour, the increased number of starts and stops effects the temperature extremes. These temperature extremes have a negative effect on the calculated soot level seen by the ECM.
Reduce the number of starts and stops by allowing the machine to idle between machine utilization. This will help sustain a constant temperature and reduce the calculated soot level errors. This step is a temporary fix until the permanent solution is implemented.G) Contact DSN.
If all the previous steps have not resolved the high soot level contact DSN before replacing the DPF. Replacing the DPF will not solve any of the known issues covered in this TIB.