20740148 Volvo.Penta Yoke

Introduction
This special instruction is a guide for troubleshooting the C3.3B and C3.8 engines that have after treatment. This document should be used when the engine is suspected of having one of the following issues:
SOS flagged with fuel dilution, wear metals, or dirt entry. SOS samples list dirt as Si (Silicon). This document will reference dirt instead of Si (Silicon)
Turbocharger failure
523602-0 high frequency regeneration code
Suspected cylinder wear (No SOS taken, dusted engine, excessive oil consumption)
Suspected plugged DPFDo not perform any procedure in this Special Instruction until you have read the information and you understand the information.Reference Section
Reference: Troubleshooting , UENR3423 , "General Information" and "Regeneration Levels of the Diesel Particulate Filter (DPF)"Reference: Troubleshooting , UENR3423 , "Diesel Particulate Filter Active Regeneration Occurrence Is Excessive"Safety Section
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.
When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.
Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.
Personal injury can result from improper handling of chemicals.Make sure you use all the necessary protective equipment required to do the job.Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.
Troubleshooting Procedure
All the information in this document is contained in the service manuals, but has been consolidated in one document for simplicity. Before beginning, there must be a good understanding of the active regeneration system for these two engines. Both use in-cylinder dosing, which is a post injection of fuel into the cylinder. The post injection sends fuel into the exhaust stream to the DOC which raises the temperature in the DPF for regeneration to occur. Read the following troubleshooting manual stories to understand this system before proceeding:
UENR3423 Troubleshooting , "General Information" and story on "Regeneration Levels of the Diesel Particulate Filter (DPF)"
UENR3423 Troubleshooting , "General Information" and story on "Diesel Particulate Filter Active Regeneration Occurrence Is Excessive"
Channel 1- C2.4, C3.3B, and C3.8 Regeneration Training
Channel 1- TIB for Fuel Dilution (523602-0 High Frequency Regeneration)Prior to troubleshooting any of these issues, the following must be done:
Obtain an Oil Sample and review results and SOS history
Confirm with the customer when the engine oil and oil filter were last changed
Cut open the oil filter and check for wear metals
Obtain a PSR and review engine codes prior to troubleshootingThe following are the five troubleshooting procedures that are based on the symptoms. Follow the first troubleshooting procedure that matches your symptom.
SOS flagged for dirt
SOS flagged for wear metals (dirt is not flagged)
Turbocharger failure
SOS with fuel dilution (no dirt, no wear metals)
523602-0 high frequency regeneration code (no flags for SOS)The following are two examples of how to use this troubleshooting guide:Example 1: If your engine has SOS flagged for dirt, wear metal, fuel dilution, and has a 523602-0 high frequency regeneration code. In that situation, the only troubleshooting procedure to follow is “SOS Flagged for Dirt”. The other symptoms are results of the dirt entry.Example 2: If your engine has SOS flagged for wear metals and fuel dilution, then refer only to “SOS Flagged for Wear Metals (dirt is not flagged)”. The fuel dilution is a result of the engine wear.SOS Flagged for Dirt:
If the SOS is flagged for dirt, dirt can cause the following: SOS flagged with fuel dilution, SOS flagged with wear metal, 523602-0 high frequency code, oil consumption, turbocharger failure, and low power. Having dirt in SOS does not automatically condemn an engine. After determining the source of dirt entry, the engine condition needs to be confirmed via compression test, and visual confirmation of cylinder walls. This information is covered in the section, “Check for Cylinder Wear” which is at the end of this document.
Check the condition of the primary air filter, secondary air filter, and the clean side of the air cleaner group.A. Are CAT filters being used ?
i. Non-CAT filter that is bypassing dirt is not supported by Caterpillar.ii. Frequently, customers will replace the air filter prior to bringing in the machine. To confirm that CAT filters were used, check parts sales for that customer to confirm how many filters were ordered versus the customer's population of SSL/CTL/MTLs.
B. Check condition of primary air filter and secondary air filter.a. If the secondary air filter is dirty, then the primary filter has been run too long.
C. Check the clean side or inside (the filters) of the air cleaner canister.
a. If there are signs of dirt, then the filters were run too long.i. Check parts sales for that customer to confirm how many filters were ordered versus the customer's population of SSL/CTL/MTLs.ii. Daily tapping of filters may damage the filter and allow dirt to bypass.
b. The recommended air filter maintenance is to clean when the E391-1 Inlet Restriction Air Filter code occurs. The only approved cleaning is using low-pressure air < 207 kPa (30 psi). After the third cleaning both the primary and secondary filter should be replaced. At a minimum, the filters should be replaced after third cleaning, annually or every 500 hrs, whichever occurs first.
c. If the customer is not going to change the air filters as per the required maintenance practice, a pre-cleaner can be installed to decrease the risk of running a filter too long.
D. Check the Product Status Report for E391-1 Inlet Air Filter Restriction