Troubleshooting

Section 5

Alarms and Troubleshooting

5.1Alarms

The EES monitors several parameters. If the EES fails to perform a successful regeneration, an alarm will be sent to alert the technician of the likely cause. This will aid in troubleshooting the system. Alarms generated by the EES are displayed as an Amber light on the EES Service Light, refer to Figure 3.8 for location.

In order to read alarms, you will need to utilize the ECM Service Tool. Refer to Section 4 for information on how to setup and use this tool.

Alarm conditions where the EES becomes inoperable will initiate a 250 hour timer. After 250 hours, the unit will shut down until the system is repaired by a qualified technician. Once the alarm condition is corrected, the EES Service Light will go from Amber to Green and the timer will be reset.

Alarm	Name	Cause / Troubleshooting
1	Back Pressure Exceeded	The system needs to regenerate but has not been able to. The back pressure is above the threshold limit where the system can automatically or manual safely regenerate 120 in/H2O (30 kPa). The EES has entered service mode. Take out the filter and perform a manual cleaning. Check for other alarms in queue and inspect the EES.
2	High Back Pressure	Back pressure is above the threshold limit where the system can automatically and safely regenerate 80 in/H2O (15kPa). The EES has entered manual mode. Activate a manual regeneration. Refer to Section 4.3. Check for other alarms in queue and inspect the EES.
3	Low Back Pressure	The back pressure has been less than 4 in/H2O (1 kPa) for more than four hours while the START/RUN/OFF switch has been active. Check the back pressure hose for cracks, leakage, or blockage. Replace the hose if damage is found.
4	Back Pressure Offset Out of Range	Check the back pressure hose for cracks, leakage or blockage. Replace the hose if damage is found. Verify back pressure by comparing an analog gauge to the transducer reading on the ECM Service Tool. Refer to Section 4.5.
5	250 Hour Service Mode	EES SERVICE REQUIRED, a 250 hour countdown timer will initiate. The time remaining before unit shutdown will be displayed on the ECM Service Tool. Refer to Section 4.4. Once the timer reaches zero, the unit will not run until the EES is repaired.
12	ECM Voltage Low	Voltage at the ECM is less than 10 Volts for 60 seconds. Inspect the connector and wires supplying power to the system. Replace the connector if damaged or corroded. Repair damaged wires.
17	Low Oil Pressure Sensor Not Connected to ECM	Digital input 3 (Engine run signal) is low and the engine has been detected running for more than 15 seconds and the alarm has been active for more than three seconds. Check the connection at the ECM. Replace the ECM if necessary.
19	Filter Inlet Temp	Filter Inlet Temperature is less than -100°C or more than 1100°C at any time. Inspect Filter Inlet Temperature Sensor (ESFIT). Refer to Section 3.6.2. Replace if necessary.
20	Temp Sensor Drift	One of the three temperature sensors differs more than +/-15°C from the average temperature of all the temperature sensors. Check the temperature value of all the temperature sensors using the ECM Service Tool. Refer to Section 4.5. Look for a temperature sensor that differs more than +/-15°C from the average temperature and replace that sensor. Temperature sensor drift is checked five hours after the ignition has been switched off.
21	Frequent Regenerations	The system is regenerating too frequently. The filter and DOC need to be checked and cleaned if necessary. The alarm is activated when the time measured between two regenerations started on back pressure gets below two hours. Alarm is cleared again when it is above two hours.
33	AR No Temperature Rise	The EES is in Start-up mode and did not reach regeneration mode three times in a row because of: •Timeout in Start-up mode •Too low Filter Inlet Temperature •Too high Filter Outlet Temperature Inspect EES components for proper functionality using manual regeneration. Refer to Section 4.3. Repair components as required.
34	Check Fuel Pump Circuit	Fuel Pump Current Draw is outside the acceptable range of 500 mA - 8.0 Amps when energized. Check fuel pump operation. Check fuse F15. Check the connector and wiring harness for damage or corrosion. Check the operation of the Fuel Pump with the ECM Service Tool. Refer to Section 4.2.
35	Check Air Control Valve	The feedback from the ACV position sensor does not correspond to the expected position. The ACV sensor output is less than ~140mV or the output is ~+/-205 mV away from the desired position for more than 15 seconds. Check fuse F15. Check the connector and wiring harness for damage or corrosion. Remove and physically inspect the valve for obstructions. Check the operation of the Air Control Valve (ACV) with the ECM Service Tool. Refer to Section 4.2.
37	Check Fuel Injector Circuit	Fuel Injector Current Draw is outside the acceptable range of 0.5 - 6.5 Amps when energized. Check fuel injector operation. Check fuse F15. Check the connector and wiring harness for damage or corrosion. Remove and physically inspect the injector for obstructions. Check the operation of the Fuel Injector with the ECM Service Tool. Refer to Section 4.2.
38	System Over Temp	Filter Outlet Temperature is more than 850°C during regeneration. In some rare cases regeneration may produce higher than expected temperatures leaving the DPF. This may be just after repairs with the back pressure still high. This indicates that there is excess soot in the DPF. In these cases, the EES will try to reduce temperatures by stopping fueling. If temperatures still exceed desired values, the unit will temporarily shut down to limit the burn rate of the soot. After about 15 minutes the unit will restart and regeneration will continue if needed.
44	Filter Outlet Temp	Filter Outlet Temperature is less than -100°C or more than 1100°C at any time. Inspect the Filter Outlet Temperature Sensor (ESFOT). Refer to Section 3.6.3. Check for exhaust leaks as this may indicate a leak in the system. Replace if necessary.
45	Exhaust Inlet Temp	Exhaust Inlet Temperature is less than -100°C or more than 1100°C at any time. Inspect the Exhaust Inlet Temperature Sensor (ESEIT). Refer to Section 3.6.1. Replace if necessary.
53	ECM Output Failure	ECM DO Current above 32A or output shorted to positive or negative supply or DO output circuits temperature above 125°C for more than two seconds. Check fuse F15. Perform a manual regeneration. Refer to Section 4.3. Replace the ECM if no outputs become energized.
54	ECM Log Failure	ECM is not able to log events. ECM internal data logger has failed. Replace the ECM.
55	ECM Clock Failure	ECM is not able to initialize. ECM internal clock has failed. Replace the ECM.
62	ECM Temp Low	ECM Temperature is less than -43°C. ECM internal temperature is below the accuracy threshold for the device. Allow the ECM to warm up. If alarm is not cleared after ECM is warmed above -38°C, replace the ECM.
63	ECM Temp High	ECM Temperature is more than 125°C. ECM internal temperature is above the accuracy threshold for the device. Allow the ECM to cool. If alarm is not cleared after ECM is cooled below 120°C, replace the ECM.

5.2Other Potential Failure Modes

•Cracked filter substrate

•Blocked Doser, lack of fuel supply, Doser problems

•Ruptured DPF housing or broken exhaust piping

•Excessive fuel and lube oil consumption

5.3Troubleshooting with the EES Service Tool

During troubleshooting, individual EES components such as the fuel pump and doser can be activated individually using the ECM Service Tool. The engine must be off and only one component can be energized at a time. Refer to Section 4.2 for complete procedures.

Air Control Valve (ACV) - Press button once to activate ACV. It will go through one cycle. You should be able to hear the motor indicating that it is working.

Injector (Doser) - Press button once to activate and once more to shut off. You should hear a clicking noise indicating that it is working.

Fuel Pump - Press button once to activate and once more to shut off. You should be able to hear the pump motor indicating that it is working.

Do not activate both the Doser and Fuel Pump at the same time. This will result in raw fuel being sprayed into the exhaust system.

5.4Operation with 250 Hour Service Mode Alarm Active

If the unit has been operating with an active “250 Hour Service Mode” alarm, it means that the 250 hour window of continued operation has started and the timer is currently counting down. When the 250 hours is over, the generator set will shut down.

During this period, automatic regeneration, initiated by either BP or the regeneration timer will not be initiated, and BP will continue to rise. In cases where BP is below 120 in/H2O (30kPa), a manual regeneration through the EES Diagnostic Tool will still be possible. If BP reaches 120 in/H2O (30kPa), manual regeneration is no longer possible; the DPF will have to be removed and manually cleaned. Refer to the DPF Manual Cleaning procedure in Section 6.4.

When back pressure is between 60 in/H2O and 120 in/H2O (15kPa and 30kPa), manual regeneration should only be initiated when the unit is running, and will continue to run in a Steady State (either high speed or low speed) for the entire regeneration process.

This may cause the unit to shut down and restart several times until the back pressure has reduced to 44 in/H2O (11kPa). The alarm “EES System Overtemp” may display and self-clear after the unit is back to normal operation. It is recommend that as part of a repair after a prolonged “EES Service Required” event that the DPF be removed and manually cleaned.