M0095947-10 (en-us)

March 2021

Troubleshooting
904J-E36TA Engine
FX (Engine)
FW (Engine)

This document has been printed from SPI2. NOT FOR RESALE
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions correctly.
Incorrect operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. You must not use
this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of
the product in the location of use, including site-specific rules and precautions applicable to the
worksite. If a tool, procedure, work method or operating technique that is not specifically
recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others.
You should also ensure that you are authorized to perform this work, and that the product will not
be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.

The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.

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 M0095947-10 3
Table of Contents

Table of Contents Exhaust System Contains Oil ............................. 139

Exhaust Temperature Is High ............................. 141
Fuel Consumption Is Excessive.......................... 144
Troubleshooting Section Fuel Contains Water.......................................... 148
Fuel Rail Pressure Problem ............................... 149
Fuel Temperature Is High................................... 153
Introduction Inlet Air Is Restricted ......................................... 155
General Information ..............................................5 Intake Manifold Air Pressure Is High ................... 156
Welding Precaution ...............................................6 Intake Manifold Air Pressure Is Low .................... 159
Intake Manifold Air Temperature Is High.............. 162
Electronic System Overview NOx Conversion Is Low ..................................... 164
System Overview ..................................................8 NRS Exhaust Gas Temperature Is High .............. 171
Component Location ...........................................10 NRS Mass Flow Rate Problem ........................... 173
Diesel Particulate Filter Regeneration ...................18 Oil Consumption Is Excessive ............................ 178
Engine Monitoring System ...................................19 Oil Contains Coolant ......................................... 180
Diagnostic Capabilities ........................................20 Oil Contains Fuel .............................................. 182
Oil Level Is Low................................................. 183
Configuration Parameters Oil Pressure Is Low ........................................... 185
Configuration Parameters ....................................21 Power Is Intermittently Low or Power Cutout Is
Intermittent...................................................... 189
Diagnostic Trouble Codes SCR Catalyst Has Incorrect Inlet Temperature..... 192
Diagnostic Trouble Codes....................................23 SCR Warning System Problem........................... 194
Transmission Oil Temperature Is High................. 203
Symptom Troubleshooting Valve Lash Is Excessive .................................... 204
Acceleration Is Poor or Throttle Response Is Poor .36
Alternator Problem (Charging Problem and/or Noisy Circuit Tests
Operation) ........................................................41 CAN Data Link - Test ......................................... 206
Battery Problem ..................................................43 Coolant Diverter - Test ....................................... 209
Clean Emissions Module Has High Oxygen Level..44 Cooling Fan Control - Test ................................. 214
Coolant Contains Oil ...........................................45 Cooling Fan Speed - Test................................... 218
Coolant Level Is Low ...........................................47 Data Link Configuration Status - Test .................. 220
Coolant Temperature Is High................................48 DEF Injector - Test............................................. 222
Coolant Temperature Is Low ................................53 DEF Line Heater - Test ...................................... 227
Cylinder Is Noisy .................................................54 DEF Pump Motor - Test ..................................... 232
DEF Does Not Purge ...........................................57 DEF Pump Pressure Sensor - Test ..................... 237
DEF Module Does Not Respond...........................58 DEF Return Valve - Test..................................... 242
DEF Pressure Is High ..........................................62 DEF Tank Sensor - Test ..................................... 249
DEF Pressure Is Low...........................................64 Electrical Power Supply - Test ............................ 253
DEF Tank Level Is Low ........................................70 Engine Speed - Test .......................................... 255
DEF Tank Temperature Is High.............................73 Ether Starting Aid - Test ..................................... 258
DEF Temperature Is Low .....................................75 Fuel Control - Test ............................................. 262
Diesel Oxidation Catalyst Has Incorrect Inlet Fuel Transfer Pump - Test.................................. 266
Temperature .....................................................79 Glow Plug Starting Aid - Test .............................. 271
Diesel Oxidation Catalyst Has Low Conversion Idle Validation - Test .......................................... 276
Efficiency ..........................................................81 Indicator Lamp - Test ......................................... 283
Diesel Particulate Filter Collects Excessive Soot....82 Injector Data Incorrect - Test .............................. 286
Diesel Particulate Filter Has Low Inlet Pressure.....86 Injector Solenoid - Test ...................................... 288
Diesel Particulate Filter Temperature Is Low ..........86 Mode Selection - Test ........................................ 295
Ether Actuation Occurrence Is Excessive ..............87 Motorized Valve - Test ....................................... 297
Engine Cranks but Does Not Start ........................91 NOx Sensor Supply - Test .................................. 304
Engine Does Not Crank .......................................98 Relay - Test (Start Relay) ................................... 306
Engine Has Early Wear...................................... 100 Relay - Test (SCR Main Relay) ........................... 308
Engine Has Mechanical Noise (Knock) ............... 102 Sensor Calibration Required - Test ..................... 312
Engine Misfires, Runs Rough or Is Unstable........ 106 Sensor (Data Link Type) - Test ........................... 314
Engine Overcrank Occurrence ........................... 111 Sensor Signal (Analog, Active) - Test .................. 318
Engine Overspeeds........................................... 114 Sensor Signal (Analog, Passive) - Test ............... 325
Engine Shutdown Occurs Intermittently .............. 117 Sensor Supply - Test ......................................... 332
Engine Shutdown While Idling ............................ 119 Speed Control (Analog) - Test ............................ 334
Engine Stalls at Low RPM.................................. 120 Speed Control (PWM) - Test............................... 340
Engine Top Speed Is Not Obtained ..................... 123 Speed/Timing - Test .......................................... 346
Engine Vibration Is Excessive ............................ 128 Switch Circuits - Test (Engine Oil Pressure
Exhaust Has Excessive Black Smoke ................. 130 Switch) ........................................................... 349
Exhaust Has Excessive White Smoke................. 133 Switch Circuits - Test (Air Filter Restriction
Exhaust System Contains Coolant...................... 137 Switch) ........................................................... 353

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Table of Contents

Switch Circuits - Test (Multiposition Throttle

Switch) ........................................................... 356
Valve Position - Test .......................................... 358
Water in Fuel - Test ........................................... 365

Service
Service Tool Features........................................ 371
Service Tool Error Identifiers .............................. 417
Customer Passwords ........................................ 425
Factory Passwords............................................ 425
ECM Will Not Accept Factory Passwords ............ 426
Electronic Service Tool Does Not Communicate .. 426
Test ECM Mode ................................................ 428
ECM Software - Install ....................................... 429
ECM - Replace ................................................. 430
DEF Pump - Replace......................................... 431
Electrical Connectors - Inspect ........................... 433
Injector Code - Calibrate .................................... 437
SCR Inducement Emergency Override ............... 439
Turbocharger - Clean ........................................ 441

Index Section
Index................................................................ 447

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 M0095947-10 5
Introduction

Troubleshooting Section Electronic Control System

The Electronic Control Module (ECM) is a computer
that controls the operation of the engine.
Introduction The ECM contains a flash file. The flash file is the
software for the ECM. The flash file contains the
operating maps. The operating maps define the
following characteristics of the engine:

i07436280 • Horsepower

General Information • Torque curves

• Engine speed (rpm)
Refer to Troubleshooting, “System Overview” for
Important Safety Information additional information on the electronic control
system.
Do not perform any procedures in this
Troubleshooting Guide until you have read the Application Interface
Operation and Maintenance Manual and you
understand this information. Use only proper tools The ECM interfaces with the machine via software
and observe all precautions that pertain to the use of and an electrical connector on the ECM. The
those tools. Failure to follow these procedures can software can be configured.
result in personal injury. The following procedures
The application control system provides inputs to the
should also be observed.
electrical connector on the ECM to indicate the status
Work safely. Most accidents that involve product of switches. Correctly configure the ECM to interpret
operation, maintenance, and repair are caused by the inputs.
failure to observe basic safety rules or precautions.
An accident can often be avoided by recognizing The ECM provides outputs for the application control
potentially hazardous situations before an accident system via the electrical connector to control lamps,
occurs. solenoids, and other devices. Correctly configure the
ECM in order for the outputs to match the
A person must be alert to potential hazards. This configuration of the application control system.
person should also have the necessary training,
skills, and tools to perform these functions properly. Clean Emissions Module (CEM)
Safety precautions and warnings are provided in this The CEM contains these components:
publication and on the product. If these hazard
warnings are not heeded, bodily injury or death could Diesel Particulate Filter (DPF) – A DPF is installed
occur to you or to other persons. Perkins cannot in the exhaust system. The DPF collects soot and
anticipate every possible circumstance that might ash from the engine exhaust.
involve a potential hazard. Diesel Oxidation Catalyst (DOC) – A DOC is
Therefore, the warnings in this publication and the installed in the exhaust system. The DOC oxidizes
warnings that are on the product are not all inclusive. hydrocarbons (HC), carbon monoxide (CO), odor
causing compounds, and soluble organic fractions
(SOF).
Overview
These engines are equipped with an electronic Selective Catalyst Reduction (SCR) System – The
control system. The system consists of a computer, SCR system is used to reduce NOx emissions from
sensors, and software. The system performs these the engine. The SCR system is installed after the
functions: DPF in the exhaust.

• Control of the engine Software – Software in the ECM monitors the DPF.
The software also controls the amount of Diesel
Exhaust Fluid (DEF) being injected into the exhaust
• Control of the Selective Catalyst Reduction (SCR) stream.
system
• Control of particulate emissions via the Clean
Emission Module (CEM)
• Applications control system interface

• Fault detection and reporting

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 6 M0095947-10
Introduction

Fault Detection and Reporting These codes are the result of a diverter valve fault.
The Diesel Exhaust Fluid (DEF) is below the
The ECM monitors inputs from the sensors and expected temperature because the diverter valve has
inputs from the applications control system. Software not allowed coolant to circulate through the DEF
in the ECM interprets the inputs. The software tank. The troubleshooting procedure to use in this
determines if the inputs are operating correctly. A case is the “Aftertreatment #1 SCR Catalyst Reagent
diagnostic trouble code is activated when the Tank #1 Heater Coolant Diverter Solenoid : Current
software detects a problem with an input. Below Normal” code, which will fix the other issue.
The ECM broadcasts the codes on the CAN data link. i07898984
If a fault is suspected with the CAN data link, refer to
Troubleshooting, “CAN Data Link - Test”.
Welding Precaution
The codes can be displayed on the electronic service
tool and optional operator interfaces. Refer to
Troubleshooting, “Diagnostic Trouble Codes” for
additional information on diagnostic trouble codes Correct welding procedures are necessary to avoid
and a complete list of codes. damage to the Electronic Control Module (ECM), to
sensors, and to associated components.
Troubleshooting Components for the driven equipment should also be
considered. When possible, remove the component
During troubleshooting, refer to the Electrical System that requires welding. When welding on an
Schematic for the application. application that is equipped with an electronically
controlled engine and removal of the component is
During troubleshooting, inspect all harness not possible, the following procedure must be
connections before any component is replaced. If followed. This procedure minimizes the risk to the
these connections are not clean and secure, electronic components.
continuous electrical faults or intermittent electrical
faults can result. Check that the wires are pushed 1. Stop the engine. Remove the electrical power from
into the connectors completely. Make sure that the the ECM.
connections are tight before other tests are made.
2. Ensure that the fuel supply to the engine is turned
Failure of an electrical component may cause the off.
failure of other components. Always attempt to
correct the cause of an electrical failure before you 3. Disconnect the negative battery cable from the
replace a component. If wire insulation is punctured, battery. If a battery disconnect switch is installed,
repair the damage. open the switch.

Troubleshooting Associated Codes 4. Disconnect all electronic components from the

wiring harnesses. Include the following
Certain systems will display multiple codes for components:
troubleshooting . These “Associated Codes” must be
used to troubleshoot the system. The codes should • Electronic components for the driven
be viewed as separate levels of troubleshooting. For equipment
example, a “DEF Tank Temperature Low” code may
be generated. This main code is not the code that • ECM
requires troubleshooting.
• Sensors
The system is designed to display the codes for this
separate level of troubleshooting as an “Associated • Electronically controlled valves
Code” . The “Associated Code” is the diagnostic or
the event code that needs to have the • Relays
troubleshooting procedure followed.
The following paragraph is an example of • Electronic control units
troubleshooting the engine system with
“ Associated Codes”” : NOTICE
Do not use electrical components (ECM or ECM sen-
After connecting the electronic service tool to an sors) or electronic component grounding points for
engine, the following codes are displayed: grounding the welder.
• Aftertreatment 1 Diesel Exhaust Fluid Tank
Temperature : Low - moderate severity

• Aftertreatment #1 SCR Catalyst Reagent Tank #1

Heater Coolant Diverter Solenoid : Current Below
Normal

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 M0095947-10 7
Introduction

Illustration 1 g01143634
Service welding guide (typical diagram)

5. When possible, connect the ground clamp for the

welding equipment directly to the engine
component that will be welded. Place the clamp as
close as possible to the weld. Close positioning
reduces the risk of welding current damage to the
engine bearings, to the electrical components, and
to other components.
6. Protect the wiring harnesses from welding debris
and/or from welding spatter.
7. Use standard welding procedures to weld the
materials together.

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 8 M0095947-10
Electronic System Overview

Electronic System The ECM adjusts timing for optimum engine

performance and for the fuel economy. Actual timing
Overview and desired timing cannot be viewed with the
electronic service tool. The ECM determines the
location of top center of the number one cylinder from
the signals that are provided by the engine speed/
timing sensors. The ECM determines when injection
i07797269
should occur relative to the top dead center position.
The ECM then provides the signal to the injector at
the correct time.
System Overview
Fuel Injection
The engine is designed for electronic control of most The common rail fuel system is controlled by the
engine operating functions. The electronic system ECM. The ECM gathers data from several sensors
consists of an Electronic Control Module (ECM), the on the engine. The ECM then uses this data to adjust
wiring harness, switches, sensors, and fuel injectors. the quantity of fuel being delivered as well as the
The engine ECM receives information from the timing of the injection event. The injection event
sensors and the switches on the engine. The engine begins when the ECM sends a signal to the injector
ECM processes the information that is collected to solenoid to actuate the valve inside the injector. As
control the engine. By altering the fuel delivery with the valve opens, the fuel flows from the fuel rail,
the fuel injectors, the engine ECM controls the speed through the fuel line, and into the injector. As the
and the power that is produced by the engine. The valve opening pressure is reached, the valve is lifted
aftertreatment system is controlled by the engine and the fuel is delivered at high pressure into the
ECM. combustion chamber.
The following information provides a general The flash file inside the ECM establishes certain
description of the control system. Refer to the limits on the amount of fuel that can be injected. The
Systems Operation manual for detailed information “Smoke Limit Fuel” is a limit that is based on the
about the control system. intake manifold pressure. The “Smoke Limit Fuel” is
used to control the air/fuel ratio for control of
System Operation emissions. When the ECM senses a higher intake
manifold pressure, the ECM increases the “Smoke
Limit Fuel” . A higher intake manifold pressure
Engine Governor indicates that there is more air in the cylinder. When
the ECM increases the “Smoke Limit Fuel” , the ECM
The ECM governs the engine. The ECM determines changes the control signal to the injector. The signal
the timing, the injection pressure, and the amount of will allow more fuel into the cylinder.
fuel that is delivered to each cylinder. These factors
are based on the actual conditions and on the The “Torque Limit Fuel” is a limit that is based on the
desired conditions at any given time during starting power rating of the engine and on the engine rpm.
and operation. The “Torque Limit Fuel” is like the rack stops and the
torque spring on a mechanically governed engine.
For variable speed engines, the ECM uses the The “Torque Limit Fuel” provides the power curves
throttle position sensor to determine the desired and the torque curves for a specific engine family and
engine speed. The ECM compares the desired a specific engine rating. All these limits are
engine speed to the actual engine speed. The actual determined at the factory. These limits cannot be
engine speed is determined through interpretation of changed.
the signals that are received by the ECM from the
engine speed/timing sensors. If the desired engine Other ECM Functions for
speed is lower than the actual engine speed, the
ECM allows more fuel to be injected, increasing Performance
engine speed. The ECM may also provide enhanced control of the
engine for functions such as controlling the cooling
Timing Considerations fan. Refer to Troubleshooting, “Configuration
Parameters” for supplementary information about the
Once the ECM has determined the amount of fuel systems that can be monitored and controlled by the
that is required, the ECM must determine the timing ECM.
of the fuel injection.

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 M0095947-10 9
Electronic System Overview

Programmable Parameters Customer passwords may be required to change

customer specified parameters.
Certain parameters that affect engine operation may
be changed with the electronic service tool. The Refer to Troubleshooting, “Configuration Parameters”
parameters are stored in the ECM, and the for additional information on this subject.
parameters are protected from unauthorized changes
by passwords. These parameters are either system Passwords
configuration parameters or customer parameters.
System configuration parameters are protected by
System configuration parameters are set at the factory passwords. Factory passwords are calculated
factory. System configuration parameters affect on a computer system that is available only to
emissions or power ratings. Factory passwords must Perkins dealers and distributors. Since factory
be obtained and factory passwords must be used to passwords contain alphabetic characters, only the
change the system configuration parameters. electronic service tool can be used to change system
configuration parameters.
Some of the parameters may affect engine operation
in an unusual way. An operator might not expect this Customer parameters can be protected by customer
type of effect. Without adequate training, these passwords. The customer passwords are
parameters may lead to power complaints or programmed by the customer. Factory passwords
performance complaints even though the engine can be used to change customer passwords if
performance is within the specification. customer passwords are lost.

Customer parameters can be used to affect the

characteristics of the engine. Limits are set by the
factory and by the monitoring system.

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 10 M0095947-10
Electronic System Overview

Refer to Troubleshooting, “Customer Passwords” additional information on this subject.

and Troubleshooting, “Factory Passwords” for
i07979125

Component Location

Electronic Control Circuit Diagram

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Electronic System Overview

Illustration 2 g06497452

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 12 M0095947-10
Electronic System Overview

Electronic control circuit diagram for an engine with a DOC, DPF, and DEF system

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 M0095947-10 13
Electronic System Overview

Sensor Locations

Illustration 3 g06369080
Sensor locations on the right side of the engine
(1) EGR temperature sensor (post-cooler) (3) DPF differential and absolute pressure (5) EGR valve
(2) Engine interface connector sensor (6) EGR differential pressure sensor
(4) Fuel rail pressure sensor (7) Coolant temperature sensor

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 14 M0095947-10
Electronic System Overview

(8) EGR temperature sensor (pre-cooler) (10) Intake throttle valve (13) Flow control valve for high-pressure
(9) Intake manifold air temperature and (11) Fuel temperature sensor fuel pump
pressure sensor (12) Secondary speed/timing sensor

Illustration 4 g06369244
Sensor locations on the left side of the engine
(14) Turbocharger electronic wastegate (15) DOC inlet temperature sensor

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 M0095947-10 15
Electronic System Overview

(16) SCR inlet temperature sensor (18) Primary speed/timing sensor

(17) DPF inlet temperature sensor (19) Engine oil pressure switch

Illustration 5 g06369291
Close up views of sensor locations on the engine
(1) EGR temperature sensor (post-cooler) (6) EGR differential pressure sensor (11) Fuel temperature sensor
(2) Engine interface connector (7) Coolant temperature sensor (12) Secondary speed/timing sensor
(3) DPF differential and absolute pressure (8) EGR temperature sensor (pre-cooler) (13) Flow control valve for high-pressure
sensor (9) Intake manifold air temperature and fuel pump
(4) Fuel rail pressure sensor pressure sensor (14) Turbocharger electronic wastegate
(5) EGR valve (10) Intake throttle valve

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Electronic System Overview

Illustration 6 g06369553
Sensors and components on the DOC/DPF/SCR aftertreatment
(1) DOC inlet temperature sensor (3) Selective Catalytic Reduction (SCR) (4) Diesel Oxidation Catalyst (DOC) and
(2) SCR inlet temperature sensor cannister Diesel Particulate Filter (DPF) cannister
(5) DPF inlet temperature sensor

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 M0095947-10 17
Electronic System Overview

Illustration 7 g06369554
Sensors and components on the DOC/DPF/SCR aftertreatment
(1) DEF injector

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Electronic System Overview

Illustration 8 g06369568 Illustration 10 g06369968

Components on the fuel filter Typical example of a NOx sensor
(1) Water in fuel sensor

Illustration 11 g06369971
Illustration 9 g06369567 Typical example of a DEF tank header
Components on the DEF Pump
(1) Electrical connector for DEF pump i07445223

Diesel Particulate Filter

Regeneration

Regeneration
The Diesel Particulate Filter (DPF) traps both soot
and ash. Regeneration is the removal of soot from
the DPF.

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 M0095947-10 19
Electronic System Overview

For additional information on the regeneration of the Note: Some parameters do not require a password
DPF, refer to Systems Operation, Testing and to be changed. Other parameters can be changed
Adjusting. with customer passwords. Certain parameters are
protected by factory passwords. Some parameters
Selective Catalyst Reduction (SCR) cannot be changed. Some applications do not allow
The SCR system is used to reduce the amount of any changes to the programmable monitoring
NOx emission from the engine. The SCR system is system. Parameters that are protected by factory
used during normal engine operation. The SCR passwords can only be changed by dealer personnel.
catalyst should not have to be cleaned or serviced. A
problem with the SCR system will cause a diagnostic Viewing or Changing the Settings
or event code to become active.
of the Monitoring System
For additional information on the SCR system, refer
to Systems Operation, Testing and Adjusting. Use the following procedure to view the parameter
settings and/or change the parameter settings:
i07496847 1. Select the “Service/Monitoring System” screen on
the electronic service tool.
Engine Monitoring System
Note: Ensure that you select the correct ECM for the
parameters that are being changed before
continuing.
The Electronic Control Module (ECM) provides a
comprehensive, programmable engine monitoring 2. Highlight the desired parameter. Then click the
system for this engine. The ECM monitors specific “Change” button in the lower left corner of the
engine operating parameters to detect abnormal screen.
conditions that may develop. The ECM will generate
an event code if a specific engine parameter exceeds The “Change Monitor System” screen will appear.
an acceptable range that is defined by the engine
monitoring system. The ECM will react with an action 3. Change the “State” of the parameter.
that depends on the severity of the condition. For
information on event codes, refer to Troubleshooting, 4. Set the “Trip Point” and the “Delay Time” according
“Event Codes”. to the “Allowed Values” that are displayed in the
lower half of the screen.
The following actions may be initiated by the ECM.
These actions depend on the severity of the 5. Click the “OK” button.
condition.
If a password is required, the “Enter Passwords”
• Illumination of a warning lamp or warning alarm screen will appear. Enter the correct passwords
and then click the “OK” button.
• Engine derate
Note: If a factory password is required, the “Enter
• Engine shutdown Factory Passwords” screen will appear. Refer to
Troubleshooting, “Factory Passwords” for information
Three possible responses may be available for each on obtaining factory passwords.
parameter. Some of the responses are not available
for some of the parameters.
The new settings will be effective immediately.
Use the electronic service tool to perform the
following activities for the monitoring system:

• Viewing parameters
• Parameter programming

• Set delay times

The default settings for the parameters are
programmed at the factory. To accommodate unique
applications and sites, some of the parameters may
be reprogrammed with the electronic service tool.
Use the electronic service tool to modify the
monitoring system parameters.

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Electronic System Overview

Note: Factory passwords are only available to Logged Codes

service technicians from an authorized Perkins
distributor. Customers of Perkins do not have access The codes are logged and stored in the ECM
to the Factory Password System (FPS). memory. The problem may have been repaired and/
or the problem may no longer exist. If the system is
i07445227
powered, an active diagnostic code may be
generated whenever a component is disconnected. If
the component is reconnected, the code is no longer
Diagnostic Capabilities active but the code may become logged.
Logged codes may not indicate that a repair is
needed. The problem may have been temporary.
Diagnostic Codes Logged codes may be useful to help troubleshoot
intermittent problems. Logged codes can also be
The engines Electronic Control Module (ECM) can used to review the performance of the engine and of
monitor the circuitry between the ECM and the the electronic system.
engines components. The ECM can also monitor the
engines operating conditions. If the ECM detects a
problem, a code is generated.
There are two categories of codes:

• Diagnostic code
• Event code
Diagnostic Code – A diagnostic code indicates an
electrical problem such as a short circuit or an open
circuit in the engines wiring or in an electrical
component.

Event Code – An event code is generated by the

detection of an abnormal engine operating condition.
For example, an event code will be generated if the
oil pressure is too low. In this case, the event code
indicates the symptom of a problem. Generally, event
codes indicate abnormal operating conditions or
mechanical problems rather than electrical problems.

Codes can have two different states:

• Active

• Logged

Active Codes
An active code indicates that a problem is present.
Service the active code first. For the appropriate
troubleshooting procedure for a particular code, refer
to the following troubleshooting procedure:
• Troubleshooting, “Diagnostic Trouble Codes”

• Troubleshooting, “Event Codes”

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 M0095947-10 21
Configuration Parameters

Configuration Parameters

i07496859

Configuration Parameters

Use this procedure if the diagnostic code in Table 1 is

active.
Table 1

J1939 Code Description Comments

630-2 Calibration Memory : Erratic, In- The Electronic Control Module (ECM) detects that one or more of the
termittent, or Incorrect programmable parameters have not been programmed.
The ECM may use a default torque map or the ECM may limit the en-
gine to low idle.
The code is active only.

The electronic service tool can be used to view

certain parameters that can affect the operation of
the engine. The electronic service tool can also be
used to change certain parameters. Some
parameters cannot be changed and some
applications do not allow any changes to the
programmable monitoring system. The parameters
are stored in the Electronic Control Module (ECM).
Some of the parameters are protected from
unauthorized changes by passwords. Parameters
that can be changed have a tattletale number. The
tattletale number shows if a parameter has been
changed.
The parameters are divided into two different types:
Customer Specified Parameters – Customer
passwords may be required to change the values of
customer specified parameters.
System Configuration Parameters – System
configuration parameters affect the emissions of the
engine or the power of the engine. Factory
passwords may be required to change the values of
system configuration parameters.

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 22 M0095947-10
Configuration Parameters

Illustration 12 g03869427
Typical configuration screen

1. Connect to the electronic service tool. Check Programmable Parameters

2. Select the Service tab. (630–2)
3. Select the Configuration tab to view the If a programmable parameter has not been
configuration parameters. programmed, the ECM will generate a 630-2
diagnostic code. The programmable parameter that
If an ECM is replaced, the appropriate parameters is not programmed will be listed under the code. The
must be copied from the old ECM. Copy the unprogrammed parameters will be set to default.
parameters with the “Copy Configuration” feature of Certain aspects of the engines performance and
the electronic service tool. The “Copy Configuration” engine monitoring may be affected.
tab is below the “Configuration” tab. Alternatively, the
settings can be recorded on paper and then
programmed into the configuration screen that is for
the new module.

NOTICE
Changing the parameters during engine operation
can cause the engine to operate erratically and can
cause engine damage.
Only change the settings of the parameters when the
engine is STOPPED.

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 M0095947-10 23
Diagnostic Trouble Codes

Diagnostic Trouble Codes

i08169768

Diagnostic Trouble Codes

Diagnostic Trouble Codes in J1939

Order
Table 2 lists the diagnostic trouble codes that apply to
the engines that are covered in this manual. The
codes are listed in J1939 order. Use the electronic
service tool to determine the codes that are active or
logged. Then refer to the appropriate troubleshooting
procedure for more information.
Table 2
List of Diagnostic Trouble Codes

J1939 Code and Description Troubleshooting Procedure

27–3
Troubleshooting, “Valve Position - Test”
EGR #1 Valve Position : Voltage Above Normal

27–4
Troubleshooting, “Valve Position - Test”
EGR #1 Valve Position : Voltage Below Normal

29–2
Accelerator Pedal Position #2 : Erratic, Intermittent, Troubleshooting, “Switch Circuits - Test (Multiposition Throttle Switch)”
or Incorrect

29–3 Troubleshooting, “Speed Control - Test (Analog)”

Accelerator Pedal Position #3 : Voltage Above or
Normal Troubleshooting, “Speed Control - Test (PWM)”

29–4 Troubleshooting, “Speed Control - Test (Analog)”

Accelerator Pedal Position #3 : Voltage Below or
Normal Troubleshooting, “Speed Control - Test (PWM)”

29–8
Accelerator Pedal Position #2 : Abnormal Frequency, Troubleshooting, “Speed Control - Test (PWM)”
Pulse Width, or Period

51–3
Troubleshooting, “Valve Position - Test”
Engine Throttle Position : Voltage Above Normal

51–4
Troubleshooting, “Valve Position - Test”
Engine Throttle Position : Voltage Below Normal

91–2
Accelerator Pedal Position #1 : Erratic, Intermittent, Troubleshooting, “Switch Circuits - Test (Multiposition Throttle Switch)”
or Incorrect

91–3 Troubleshooting, “Speed Control - Test (Analog)”

Accelerator Pedal Position #1 : Voltage Above or
Normal Troubleshooting, “Speed Control - Test (PWM)”

91–4 Troubleshooting, “Speed Control - Test (Analog)”

Accelerator Pedal Position #1 : Voltage Below or
Normal Troubleshooting, “Speed Control - Test (PWM)”

(continued)

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 24 M0095947-10
Diagnostic Trouble Codes

(Table 2, contd)
91–8
Accelerator Pedal Position #1 : Abnormal Frequency, Troubleshooting, “Speed Control - Test (PWM)”
Pulse Width, or Period

97–3
Troubleshooting, “Water in Fuel - Test”
Water In Fuel Indicator : Voltage Above Normal

97–15
Troubleshooting, “Fuel Contains Water”
Water In Fuel Indicator : High - least severe (1)

97–16
Troubleshooting, “Fuel Contains Water”
Water In Fuel Indicator : High - moderate severity (2)

98–1
Troubleshooting, “Oil Level Is Low”
Engine Oil Level : Low - most severe (3)

98–17
Troubleshooting, “Oil Level Is Low”
Engine Oil Level : Low - least severe (1)

98–18
Troubleshooting, “Oil Level Is Low”
Engine Oil Level : Low - moderate severity (2)

100–1
Troubleshooting, “Oil Pressure Is Low”
Engine Oil Pressure : Low - most severe (3)

100–2
Engine Oil Pressure : Erratic, Intermittent, or Troubleshooting, “Switch Circuits - Test (Oil Pressure Switch)”
Incorrect
102–16
Engine Intake Manifold #1 Pressure : High - moder- Troubleshooting, “Intake Manifold Air Pressure Is High”
ate severity (2)

102–18
Engine Intake Manifold #1 Pressure : Low - moder- Troubleshooting, “Intake Manifold Air Pressure Is Low”
ate severity (2)

105–0
Engine Intake Manifold #1 Temperature : High - most Troubleshooting, “Intake Manifold Air Temperature Is High”
severe (3)

105–3
Engine Intake Manifold #1 Temperature : Voltage Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Above Normal
105–4
Engine Intake Manifold #1 Temperature : Voltage Be- Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
low Normal
105–15
Engine Intake Manifold #1 Temperature : High - least Troubleshooting, “Intake Manifold Air Temperature Is High”
severe (1)

105–16
Engine Intake Manifold #1 Temperature : High - mod- Troubleshooting, “Intake Manifold Air Temperature Is High”
erate severity (2)

107–3
Engine Air Filter 1 Differential Pressure : Voltage Troubleshooting, “Switch Circuits - Test (Air Filter Restriction Switch)”
Above Normal
107–4
Engine Air Filter 1 Differential Pressure : Voltage Be- Troubleshooting, “Switch Circuits - Test (Air Filter Restriction Switch)”
low Normal
107–15
Engine Air Filter 1 Differential Pressure high - least Troubleshooting, “Inlet Air Is Restricted”
severe (1)

(continued)

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 M0095947-10 25
Diagnostic Trouble Codes

(Table 2, contd)
107–16
Engine Air Filter 1 Differential Pressure high - moder- Troubleshooting, “Inlet Air Is Restricted”
ate severity (2)

108–12
Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Barometric Pressure : Failure
110–0
Troubleshooting, “Coolant Temperature Is High”
Engine Coolant Temperature : High - most severe (3)

110–3
Engine Coolant Temperature : Voltage Above Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Normal
110–4
Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Engine Coolant Temperature : Voltage Below Normal

110–15
Troubleshooting, “Coolant Temperature Is High”
Engine Coolant Temperature : High - least severe (1)

110–16
Engine Coolant Temperature : High - moderate se- Troubleshooting, “Coolant Temperature Is High”
verity (2)

111–1
Troubleshooting, “Coolant Level Is Low”
Engine Coolant Level : Low - most severe (3)

111–17
Troubleshooting, “Coolant Level Is Low”
Engine Coolant Level : Low - least severe (1)

111–18
Troubleshooting, “Coolant Level Is Low”
Engine Coolant Level : Low - moderate severity (2)

157–3
Engine Injector Metering Rail #1 Pressure : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Above Normal
157–4
Engine Injector Metering Rail #1 Pressure : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Below Normal
157–12
Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Engine Injector Metering Rail #1 Pressure : Failure

157–16
Engine Injector Metering Rail #1 Pressure : High - Troubleshooting, “Fuel Rail Pressure Problem”
moderate severity (2)

157–18
Engine Injector Metering Rail #1 Pressure : Low - Troubleshooting, “Fuel Rail Pressure Problem”
moderate severity (2)

168–15
Battery Potential / Power Input #1 : High - least se- Troubleshooting, “Electrical Power Supply - Test”
vere (1)

168–17
Battery Potential / Power Input #1 : Low - least se- Troubleshooting, “Electrical Power Supply - Test”
vere (1)

168–31
Troubleshooting, “Battery Problem”
Battery Potential / Power Input #1

172–3
Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Engine Air Inlet Temperature : Voltage Above Normal

172–4
Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Engine Air Inlet Temperature : Voltage Below Normal

(continued)

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 26 M0095947-10
Diagnostic Trouble Codes

(Table 2, contd)
174–3
Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Engine Fuel Temperature 1 : Voltage Above Normal

174–4
Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Engine Fuel Temperature 1 : Voltage Below Normal

174–16
Engine Fuel Temperature 1 : High - moderate se- Troubleshooting, “Fuel Temperature Is High”
verity (2)

177–0
Transmission Oil Temperature : High - most severe Troubleshooting, “Transmission Oil Temperature Is High”
(3)

177–3
Transmission Oil Temperature : Voltage Above Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Normal
177–4
Transmission Oil Temperature : Voltage Below Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Normal
177–15
Transmission Oil Temperature : High - least severe Troubleshooting, “Transmission Oil Temperature Is High”
(1)

177–16
Transmission Oil Temperature : High - moderate se- Troubleshooting, “Transmission Oil Temperature Is High”
verity (2)

190–0
Troubleshooting, Engine Overspeeds
Engine Speed : High - most severe (3)

190–8
Engine Speed : Abnormal Frequency, Pulse Width, Troubleshooting, Speed/Timing - Test
or Period
190–10
Troubleshooting, Engine Speed - Test
Engine Speed : Abnormal Rate of Change

190–15
Troubleshooting, Engine Overspeeds
Engine Speed : High - least severe (1)

411–3
Troubleshooting, “Sensor Signal (Analog, Active) - Test”
EGR Differential Pressure : Voltage Above Normal

411–4
Troubleshooting, “Sensor Signal (Analog, Active) - Test”
EGR Differential Pressure : Voltage Below Normal

411–13
Troubleshooting, Sensor Calibration Required - Test
EGR Differential Pressure : Out of Calibration
412–3
Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
EGR Temperature : Voltage Above Normal

412–4
Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
EGR Temperature : Voltage Below Normal

412–15
Troubleshooting, “NRS Exhaust Gas Temperature Is High”
EGR Temperature : High - least severe (1)

412–16
Troubleshooting, “NRS Exhaust Gas Temperature Is High”
EGR Temperature : High - moderate severity (2)

441–0 Troubleshooting depends on the function of the auxiliary temperature sensor which is de-
Auxiliary Temperature #1 : High - most severe (3) fined by the OEM for the application.

(continued)

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 M0095947-10 27
Diagnostic Trouble Codes

(Table 2, contd)
441–3
Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Auxiliary Temperature #1 : Voltage Above Normal

441–4
Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Auxiliary Temperature #1 : Voltage Below Normal

441–15 Troubleshooting depends on the function of the auxiliary temperature sensor which is de-
Auxiliary Temperature #1 : High - least severe (1) fined by the OEM for the application.

441–16
Troubleshooting depends on the function of the auxiliary temperature sensor which is de-
Auxiliary Temperature #1 : High - moderate severity
fined by the OEM for the application.
(2)

558–2
Accelerator Pedal #1 Low Idle Switch : Erratic, Inter- Troubleshooting, “Idle Validation - Test”
mittent, or Incorrect

593–31
Troubleshooting, “Engine Shutdown While Idling”
Engine Idle Shutdown has Shutdown Engine

594–0
Engine Idle Shutdown Driver Alert Mode : High - Troubleshooting, “Engine Shutdown While Idling”
most severe (3)

594–31
Troubleshooting, “Engine Shutdown While Idling”
Engine Idle Shutdown Driver Alert Mode

626–5
Engine Start Enable Device 1 : Current Below Troubleshooting, “Ether Starting Aid - Test”
Normal
626–6
Engine Start Enable Device 1 : Current Above Troubleshooting, “Ether Starting Aid - Test”
Normal
630-2
Calibration Memory : Erratic, Intermittent, or Troubleshooting, “Configuration Parameters”
Incorrect
631–2
Troubleshooting, “ECM Software - Install”
Personality Module : Erratic, Intermittent, or Incorrect

637–11
Troubleshooting, “Speed/Timing - Test”
Engine Timing Sensor : Other Failure Mode

639–9
Troubleshooting, “CAN Data Link - Test”
J1939 Network #1 : Abnormal Update Rate

639–14
Troubleshooting, “Data Link Configuration Status - Test”
J1939 Network #1 : Special Instruction

651–2
Engine Injector Cylinder #01 : Erratic, Intermittent, or Troubleshooting, “Injector Data Incorrect - Test”
Incorrect
651–5
Troubleshooting, “Injector Solenoid - Test”
Engine Injector Cylinder #01 : Current Below Normal

651–6
Troubleshooting, “Injector Solenoid - Test”
Engine Injector Cylinder #01 : Current Above Normal

652–2
Engine Injector Cylinder #02 : Erratic, Intermittent, or Troubleshooting, “Injector Data Incorrect - Test”
Incorrect
652–5
Troubleshooting, “Injector Solenoid - Test”
Engine Injector Cylinder #02 : Current Below Normal

(continued)

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 28 M0095947-10
Diagnostic Trouble Codes

(Table 2, contd)
652–6
Troubleshooting, “Injector Solenoid - Test”
Engine Injector Cylinder #02 : Current Above Normal

653–2
Engine Injector Cylinder #03 : Erratic, Intermittent, or Troubleshooting, “Injector Data Incorrect - Test”
Incorrect
653–5
Troubleshooting, “Injector Solenoid - Test”
Engine Injector Cylinder #03 : Current Below Normal

653–6
Troubleshooting, “Injector Solenoid - Test”
Engine Injector Cylinder #03 : Current Above Normal

654–2
Engine Injector Cylinder #04 : Erratic, Intermittent, or Troubleshooting, “Injector Data Incorrect - Test”
Incorrect
654–5
Troubleshooting, “Injector Solenoid - Test”
Engine Injector Cylinder #04 : Current Below Normal

654–6
Troubleshooting, “Injector Solenoid - Test”
Engine Injector Cylinder #04 : Current Above Normal

676–5
Troubleshooting, “Glow Plug Starting Aid - Test”
Engine Glow Plug Relay : Current Below Normal

676–6
Troubleshooting, “Glow Plug Starting Aid - Test”
Engine Glow Plug Relay : Current Above Normal

677–5
Troubleshooting, “Relay - Test (Start Relay)”
Engine Starter Motor Relay Current Above Normal

677–6
Troubleshooting, “Relay - Test (Start Relay)”
Engine Starter Motor Relay Current Below Normal

723–8
Engine Speed Sensor #2 : Abnormal Frequency, Troubleshooting, “Speed/Timing - Test”
Pulse Width, or Period

977–5
Troubleshooting, “Cooling Fan Control - Test”
Fan Drive State : Current Below Normal
977–6
Troubleshooting, “Cooling Fan Control - Test”
Fan Drive State : Current Above Normal
1075–5
Engine Electric Lift Pump for Engine Fuel Supply : Troubleshooting, “Fuel Transfer Pump - Test”
Current Below Normal
1075–6
Engine Electric Lift Pump for Engine Fuel Supply : Troubleshooting, “Fuel Transfer Pump - Test”
Current Above Normal
1076–5
Engine Fuel Injection Pump Fuel Control Valve : Cur- Troubleshooting, “Fuel Control - Test”
rent Below Normal
1076–6
Engine Fuel Injection Pump Fuel Control Valve : Cur- Troubleshooting, “Fuel Control - Test”
rent Above Normal
1188–3
Engine Turbocharger #1 Wastegate Drive : Voltage Troubleshooting, “Valve Position - Test”
Above Normal
1188–4
Engine Turbocharger #1 Wastegate Drive : Voltage Troubleshooting, “Valve Position - Test”
Below Normal

(continued)

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 M0095947-10 29
Diagnostic Trouble Codes

(Table 2, contd)
1188–7
Engine Turbocharger #1 Wastegate Drive : Not Re- Troubleshooting, “Motorized Valve - Test”
sponding Properly

1235–9
Troubleshooting, “CAN Data Link - Test”
J1939 Network #3 : Abnormal Update Rate

1387–0 Troubleshooting depends on the function of the auxiliary pressure sensor which is de-
Auxiliary Pressure #1 : High - most severe (3) fined by the OEM for the application.

1387–1 Troubleshooting depends on the function of the auxiliary pressure sensor which is de-
Auxiliary Pressure #1 : Low - most severe (3) fined by the OEM for the application.

1387–3
Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Auxiliary Pressure #1 : Voltage Above Normal

1387–4
Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Auxiliary Pressure #1 : Voltage Below Normal

1387–15 Troubleshooting depends on the function of the auxiliary pressure sensor which is de-
Auxiliary Pressure #1 : High - least severe (1) fined by the OEM for the application.

1387–16 Troubleshooting depends on the function of the auxiliary pressure sensor which is de-
Auxiliary Pressure #1 : High - moderate severity (2) fined by the OEM for the application.

1387–17 Troubleshooting depends on the function of the auxiliary pressure sensor which is de-
Auxiliary Pressure #1 : Low - least severe (1) fined by the OEM for the application.

1387–18 Troubleshooting depends on the function of the auxiliary pressure sensor which is de-
Auxiliary Pressure #1 : Low - moderate severity (2) fined by the OEM for the application.

1639–17
Troubleshooting, “Cooling Fan Speed - Test”
Fan Speed : Low - least severe (1)

1664–31
Troubleshooting, “Engine Overcrank Occurrence”
Engine Automatic Start Failed

1761–1
Aftertreatment #1 DEF Tank Volume #1 : Low - most Troubleshooting, “DEF Tank Level Is Low”
severe (3)

1761–2
Aftertreatment #1 DEF Tank Volume #1 : Erratic, In- Troubleshooting, “DEF Tank Sensor - Test”
termittent, or Incorrect

1761–12
Troubleshooting, “DEF Tank Sensor - Test”
Aftertreatment #1 DEF Tank Volume #1 : Failure
1761–17
Aftertreatment #1 DEF Tank Volume #1 : Low - least Troubleshooting, “DEF Tank Level Is Low”
severe (1)

1761–18
Aftertreatment #1 DEF Tank Volume #1 : Low - mod- Troubleshooting, “DEF Tank Level Is Low”
erate severity (2)

2630–3
Engine Charge Air Cooler Outlet Temperature : Volt- Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
age Above Normal

2630–4
Engine Charge Air Cooler Outlet Temperature : Volt- Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
age Below Normal

2659–7
Troubleshooting, “NRS Mass Flow Rate Problem”
EGR Mass Flow Rate : Not Responding Properly

(continued)

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 30 M0095947-10
Diagnostic Trouble Codes

(Table 2, contd)
2791–5
Troubleshooting, “Motorized Valve - Test”
EGR Valve Control : Current Below Normal
2791–6
Troubleshooting, “Motorized Valve - Test”
EGR Valve Control : Current Above Normal
2791–7
Troubleshooting, “Motorized Valve - Test”
EGR Valve Control : Not Responding Properly

2882–2
Engine Alternate Rating Select : Erratic, Intermittent, Troubleshooting, “Mode Selection - Test”
or Incorrect
2970–2
Accelerator Pedal #2 Low Idle Switch : Erratic, Inter- Troubleshooting, “Idle Validation - Test”
mittent, or Incorrect

3031–7
Aftertreatment #1 DEF Tank Temperature : Not Re- Troubleshooting, “DEF Tank Temperature Is Low”
sponding Properly

3031–12
Troubleshooting, “DEF Tank Sensor - Test”
Aftertreatment #1 DEF Tank Temperature : Failure

3031–16
Aftertreatment #1 DEF Tank Temperature : High - Troubleshooting, “DEF Tank Temperature Is High”
moderate severity (2)

3031–18
Aftertreatment #1 DEF Tank Temperature : Low - Troubleshooting, “DEF Tank Temperature Is Low”
moderate severity (2)

3216–7
Aftertreatment #1 Intake NOx : Not Responding Troubleshooting, “NOx Sensor - Test”
Properly

3216–12
Troubleshooting, “Sensor (Data Link Type) - Test”
Aftertreatment #1 Intake NOx : Failure
3217-16
Aftertreatment #1 Intake O2 : High - moderate se- Troubleshooting, “Clean Emissions Module Has High Oxygen Level”
verity (2)

3226–12
Troubleshooting, “Sensor (Data Link Type) - Test”
Aftertreatment #1 Outlet NOx : Failure
3227-16
Aftertreatment #1 Outlet O2 : High - moderate se- Troubleshooting, “Clean Emissions Module Has High Oxygen Level”
verity (2)

3242–18
Aftertreatment #1 DPF Intake Temperature : Low - Troubleshooting, “Diesel Particulate Filter Temperature Is Low”
moderate severity (2)

3251–1
Aftertreatment #1 DPF Differential Pressure : Low - Troubleshooting, “Diesel Particulate Filter Has Low Inlet Pressure”
most severe (3)

3251–3
Aftertreatment #1 DPF Differential Pressure : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Above Normal
3251–4
Aftertreatment #1 DPF Differential Pressure : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
Below Normal
3251–13
Aftertreatment #1 DPF Differential Pressure : Out of Troubleshooting, “Sensor Calibration Required - Test”
Calibration

(continued)

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 M0095947-10 31
Diagnostic Trouble Codes

(Table 2, contd)
3251–16
Aftertreatment #1 DPF Differential Pressure High: Troubleshooting, “Diesel Particulate Filter Collects Excessive Soot”
Moderate Severity (2)

3251–18
Aftertreatment #1 DPF Differential Pressure : Low - Troubleshooting, “Diesel Particulate Filter Has Low Inlet Pressure”
moderate severity (2)

3358–3
Troubleshooting, “Sensor Signal (Analog, Active) - Test”
EGR Inlet Pressure : Voltage Above Normal

3358–4
Troubleshooting, “Sensor Signal (Analog, Active) - Test”
EGR Inlet Pressure : Voltage Below Normal

3358–13
Troubleshooting, “Sensor Calibration Required - Test”
EGR Inlet Pressure : Out of Calibration
3361–5
Aftertreatment #1 DEF Dosing Unit : Current Below Troubleshooting, “DEF Injector - Test”
Normal
3361–6
Aftertreatment #1 DEF Dosing Unit : Current Above Troubleshooting, “DEF Injector - Test”
Normal
3361–7
Aftertreatment #1 DEF Dosing Unit : Not Responding Troubleshooting, “DEF Module Does Not Respond”
Properly

3362–14
Aftertreatment #1 DEF Dosing Unit Input Lines : Spe- Troubleshooting, “DEF Does Not Purge”
cial Instruction
3363–5
Aftertreatment #1 DEF Tank Heater : Current Below Troubleshooting, “Coolant Diverter - Test”
Normal
3363–6
Aftertreatment #1 DEF Tank Heater : Current Above Troubleshooting, “Coolant Diverter - Test”
Normal
3464–5
Engine Throttle Actuator 1 Control Command : Cur- Troubleshooting, “Motorized Valve - Test”
rent Below Normal
3464–6
Engine Throttle Actuator 1 Control Command : Cur- Troubleshooting, “Motorized Valve - Test”
rent Above Normal
3464–7
Engine Throttle Actuator 1 Control Command : Not Troubleshooting, “Motorized Valve - Test”
Responding Properly

3509–3
Troubleshooting, “Sensor Supply - Test”
Sensor Supply Voltage 1 : Voltage Above Normal

3509–4
Troubleshooting, “Sensor Supply - Test”
Sensor Supply Voltage 1 : Voltage Below Normal

3510–3
Troubleshooting, “Sensor Supply - Test”
Sensor Supply Voltage 2 : Voltage Above Normal

3510–4
Troubleshooting, “Sensor Supply - Test”
Sensor Supply Voltage 2 : Voltage Below Normal

3516–2
Aftertreatment #1 DEF Concentration : Erratic, Inter- Troubleshooting, “DEF Tank Sensor - Test”
mittent, or Incorrect

(continued)

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 32 M0095947-10
Diagnostic Trouble Codes

(Table 2, contd)
3516–11
Aftertreatment #1 DEF Concentration : Other Failure Troubleshooting, “NOx Conversion Is Low”
Mode
3516–12
Troubleshooting, “DEF Tank Sensor - Test”
Aftertreatment #1 DEF Concentration : Failure
3516–15
Aftertreatment #1 DEF Concentration : High - least Troubleshooting, “NOx Conversion Is Low”
severe (1)

3516–18
Aftertreatment #1 DEF Concentration : Low - moder- Troubleshooting, “NOx Conversion Is Low”
ate severity (2)

3563–3
Engine Intake Manifold #1 Absolute Pressure : Volt- Troubleshooting, “Sensor Signal (Analog, Active) - Test”
age Above Normal

3563–4
Engine Intake Manifold #1 Absolute Pressure : Volt- Troubleshooting, “Sensor Signal (Analog, Active) - Test”
age Below Normal

3563–13
Engine Intake Manifold #1 Absolute Pressure : Out Troubleshooting, “Sensor Calibration Required - Test”
of Calibration
3609–3
Troubleshooting, “Sensor Signal (Analog, Active) - Test”
DPF #1 Intake Pressure : Voltage Above Normal

3609–4
Troubleshooting, “Sensor Signal (Analog, Active) - Test”
DPF #1 Intake Pressure : Voltage Below Normal

3609–13
Troubleshooting, “Sensor Calibration Required - Test”
DPF #1 Intake Pressure : Out of Calibration
3714–31
Diesel Particulate Filter Active Regeneration Inhib- Troubleshooting, “Diesel Particulate Filter Collects Excessive Soot”
ited Due to Temporary System Lockout

3715–31
Diesel Particulate Filter Active Regeneration Inhib- Troubleshooting, “Diesel Particulate Filter Collects Excessive Soot”
ited Due to Permanent System Lockout

3719–0
DPF #1 Soot Loading Percent : High - most severe Troubleshooting, “Diesel Particulate Filter Collects Excessive Soot”
(3)

3719–16
DPF #1 Soot Loading Percent : High - moderate se- Troubleshooting, “Diesel Particulate Filter Collects Excessive Soot”
verity (2)

4334–3
Aftertreatment 1 Diesel Exhaust Fluid Doser Abso- Troubleshooting, “DEF Pump Pressure Sensor - Test”
lute Pressure: Voltage Above Normal

4334–4
Aftertreatment 1 Diesel Exhaust Fluid Doser Abso- Troubleshooting, “DEF Pump Pressure Sensor - Test”
lute Pressure: Voltage Below Normal

4334–7
Aftertreatment 1 Diesel Exhaust Fluid Doser Abso- Troubleshooting, “DEF Pressure Is Low”
lute Pressure: Not Responding Properly

4334–15
Aftertreatment #1 DEF #1 Pressure (absolute) : High Troubleshooting, “DEF Pressure Is High”
- least severe (1)

(continued)

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 M0095947-10 33
Diagnostic Trouble Codes

(Table 2, contd)
4334–16
Aftertreatment #1 DEF #1 Pressure (absolute) : High Troubleshooting, “DEF Pressure Is High”
- moderate severity (2)

4334–18
Aftertreatment #1 DEF #1 Pressure (absolute) : Low Troubleshooting, “DEF Pressure Is Low”
- moderate severity (2)

4337–8
Aftertreatment #1 DEF Doser #1 Temperature : Ab- Troubleshooting, “DEF Pump - Replace”
normal Frequency, Pulse Width, or Period

4354–5
Aftertreatment #1 DEF Line Heater #1 : Current Be- Troubleshooting, “DEF Line Heater - Test”
low Normal
4354–6
Aftertreatment #1 DEF Line Heater #1 : Current Troubleshooting, “DEF Line Heater - Test”
Above Normal
4355–5
Aftertreatment #1 DEF Line Heater #2 : Current Be- Troubleshooting, “DEF Line Heater - Test”
low Normal
4355–6
Aftertreatment #1 DEF Line Heater #2 : Current Troubleshooting, “DEF Line Heater - Test”
Above Normal
4356–5
Aftertreatment #1 DEF Line Heater #3 : Current Be- Troubleshooting, “DEF Line Heater - Test”
low Normal
4356–6
Aftertreatment #1 DEF Line Heater #3 : Current Troubleshooting, “DEF Line Heater - Test”
Above Normal
4360–10
Aftertreatment #1 SCR Catalyst Intake Gas Temper- Troubleshooting, “SCR Catalyst Has Incorrect Inlet Temperature”
ature : Abnormal Rate of Change

4360–16
Aftertreatment #1 SCR Catalyst Intake Gas Temper- Troubleshooting, “SCR Catalyst Has Incorrect Inlet Temperature”
ature : High - moderate severity (2)

4360–17
Aftertreatment #1 SCR Catalyst Intake Gas Temper- Troubleshooting, “SCR Catalyst Has Incorrect Inlet Temperature”
ature : Low - least severe (1)

4360–18
Aftertreatment #1 SCR Catalyst Intake Gas Temper- Troubleshooting, “SCR Catalyst Has Incorrect Inlet Temperature”
ature : Low - moderate severity (2)

4364–2
Aftertreatment #1 SCR Catalyst Conversion Effi- Troubleshooting, “NOx Conversion Is Low”
ciency : Erratic, Intermittent, or Incorrect

4364–18
Aftertreatment #1 SCR Catalyst Conversion Effi- Troubleshooting, “NOx Conversion Is Low”
ciency : Low - moderate severity (2)

4374–3
Aftertreatment #1 DEF Pump #1 Motor Speed : Volt- Troubleshooting, “DEF Pump Motor - Test”
age Above Normal

4374–4
Aftertreatment #1 DEF Pump #1 Motor Speed : Volt- Troubleshooting, “DEF Pump Motor - Test”
age Below Normal

(continued)

This document has been printed from SPI2. NOT FOR RESALE
 34 M0095947-10
Diagnostic Trouble Codes

(Table 2, contd)
4374–5
Aftertreatment #1 DEF Pump #1 Motor Speed : Cur- Troubleshooting, “DEF Pump Motor - Test”
rent Below Normal
4374–6
Aftertreatment #1 DEF Pump #1 Motor Speed : Cur- Troubleshooting, “DEF Pump Motor - Test”
rent Above Normal
4374–8
Aftertreatment #1 DEF Pump #1 Motor Speed : Ab- Troubleshooting, “DEF Pump - Replace”
normal Frequency, Pulse Width, or Period

4376–5
Aftertreatment #1 DEF Return Valve : Current Below Troubleshooting, “DEF Return Valve - Test”
Normal
4376–6
Aftertreatment #1 DEF Return Valve : Current Above Troubleshooting, “DEF Return Valve - Test”
Normal
4376–7
Aftertreatment #1 DEF Return Valve : Not Respond- Troubleshooting, “DEF Return Valve - Test”
ing Properly

4376–14
Aftertreatment #1 DEF Return Valve : Special Troubleshooting, “DEF Return Valve - Test”
Instruction
4750–3
EGR Cooler Inlet Temperature : Voltage Above Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Normal
4750–4
EGR Cooler Inlet Temperature : Voltage Below Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
Normal
4765–17
Aftertreatment #1 Diesel Oxidation Catalyst Intake Troubleshooting, “Diesel Oxidation Catalyst Has Incorrect Inlet Temperature”
Gas Temperature : Low - least severe (1)

5246–0
Aftertreatment SCR Operator Inducement Severity : Troubleshooting, “SCR Warning System Problem”
High - most severe (3)

5246–15
Aftertreatment SCR Operator Inducement Severity : Troubleshooting, “SCR Warning System Problem”
High - least severe (1)

5246–16
Aftertreatment SCR Operator Inducement Severity : Troubleshooting, “SCR Warning System Problem”
High - moderate severity (2)

5298–17
Aftertreatment 1 Diesel Oxidation Catalyst Conver- Troubleshooting, “Diesel Oxidation Catalyst Has Low Conversion Efficiency”
sion Efficiency : Low - least severe (1)

5392–31
Troubleshooting, “DEF Pressure Is Low”
Aftertreatment #1 DEF Dosing Unit #1 Loss of Prime

5421–5
Engine Turbocharger Wastegate Actuator #1 : Cur- Troubleshooting, “Motorized Valve - Test”
rent Below Normal
5421–6
Engine Turbocharger Wastegate Actuator #1 : Cur- Troubleshooting, “Motorized Valve - Test”
rent Above Normal

(continued)

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 M0095947-10 35
Diagnostic Trouble Codes

(Table 2, contd)
5571–0
High Pressure Common Rail Fuel Pressure Relief Troubleshooting, “Fuel Rail Pressure Problem”
Valve : High - most severe (3)

5742–12
Aftertreatment Diesel Particulate Filter Temperature Troubleshooting, “Sensor (Data Link Type) - Test”
Sensor Module : Failure
5743–12
Aftertreatment 1 SCR Temperature Sensor Module : Troubleshooting, “Sensor (Data Link Type) - Test”
Failure
5758–11
Aftertreatment #1 Intake Gas Sensor Power Supply : Troubleshooting, “NOx Sensor Supply - Test”
Other Failure Mode
5759–11
Aftertreatment #1 Outlet Gas Sensor Power Supply : Troubleshooting, “NOx Sensor Supply - Test”
Other Failure Mode
5798–7
Aftertreatment #1 DEF Dosing Unit Heater Tempera- Troubleshooting, “DEF Tank Temperature Is Low”
ture : Not Responding Properly

5965–5
Aftertreatment #1 DEF Control Module Relay Control Troubleshooting, “Relay - Test (SCR Main Relay)”
: Current Below Normal
5965–6
Aftertreatment #1 DEF Control Module Relay Control Troubleshooting, “Relay - Test (SCR Main Relay)”
: Current Above Normal
7105–31
Aftertreatment #1 Inconsistent Configuration Troubleshooting, “NOx Conversion Is Low”
Detected
7343–31
SCR Operator Inducement Override Renewal Troubleshooting, “SCR Inducement Emergency Override”
Required

8631–17
Engine Turbocharger #1 Efficiency: Low – Least Troubleshooting, Turbocharger - Clean
Severe
8631–18
Engine Turbocharger #1 Efficiency: Low – Moderate Troubleshooting, Turbocharger - Clean
Severity

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 36 M0095947-10
Symptom Troubleshooting

Symptom Troubleshooting

i08072457

Acceleration Is Poor or
Throttle Response Is Poor

Check the electronic service tool for any associated

codes that are listed in Table 3 . Troubleshoot any
active codes before continuing with this procedure.
Table 3
Associated Diagnostic Trouble Codes

J1939 Code
107–15
107–16

Probable Causes
• Diagnostic codes
• Parameters in the Electronic Control Module
(ECM)

• Oil pressure
• Throttle Signal

• Air Inlet and Exhaust System

• Turbocharger

• Fuel System
• Engine Load

• Valve Lash
• Low compression (cylinder pressure)

• Electronic unit injectors

• Individual malfunctioning cylinder

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

Note: If the problem only occurs under certain

conditions, test the engine under those conditions.
Examples of certain conditions are high engine
speed, full load, and engine operating temperature.
Troubleshooting the symptoms under other
conditions can give misleading results.

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 M0095947-10 37
Symptom Troubleshooting

Table 4
Troubleshooting Test Steps Values Results

1. Engine Derate or Active Codes Engine Derate Result: A diagnostic code is present.
or Active Codes
A. Certain diagnostic codes and/or event codes may cause poor Repair: Troubleshoot the code and then reset the
performance. Refer to the histogram information for engine de- histogram.
rates in the electronic service tool. Check for the following
histograms: Result: A diagnostic code is not present.
Proceed to Test Step 2.
1. High Exhaust Temperature Prevention Derate Time Histogram

2. High Turbo Speed Prevention Derate Time Histogram

B. If the histograms contain derates and no diagnostic codes are

present, then the engine is operating normally. The following list
contains conditions that can cause derates:

1. Elevated altitude

2. Elevated inlet air temperature

3. Elevated ambient temperature

2. Incorrect Parameters Parameters Result: The parameters are correct.

A. Use the electronic service tool to verify that the correct param- Proceed to Test Step 3.
eters are being used. Refer to Troubleshooting, “Configuration
Parameters” for additional information. Result: The parameters are not correct.

Repair: Input the correct parameters. Refer to Trouble-

shooting, “Configuration Parameters” for additional
information.

3. Oil Pressure Oil pressure Result: The oil pressure is not OK.

Note: When the engine is started, the turbocharger protection Repair: Make any necessary repairs. Refer to Trouble-
strategy will lock the engine speed at low idle until the oil pressure shooting, Oil Pressure Is Low.
builds or the engine has been running for 60 seconds.
A. Ensure that the engine oil pressure is sufficient. Refer to Trou- Result: The oil pressure is OK.
bleshooting, Oil Pressure Is Low.
Proceed to Test Step 4.

4. Throttle Signal Throttle Signal Result: The throttle signal is stable.

Proceed to Test Step 5.
A. Monitor the status for “Throttle Position” on the electronic serv-
ice tool. Verify that the status for “Throttle Position” is stable and Result: The throttle signal is not stable.
that the engine is able to reach high idle speed.
Repair: Make the necessary repairs, Refer to the appro-
priate circuit test.

(continued)

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 38 M0095947-10
Symptom Troubleshooting

(Table 4, contd)

5. Restriction in the Air Inlet and Exhaust System Restrictions Result: There are no restrictions in the air inlet or exhaust
system.
A. Observe the check engine lamp. Check for an air filter restric-
tion indicator. Replace any plugged air filters. Refer to the Opera- Proceed to Test Step 6.
tion and Maintenance Manual.
Result: There are restrictions in the air inlet or exhaust
B. Check the air inlet and exhaust system for restrictions and/or system.
leaks.
Repair: Make the necessary repairs, Refer to Systems
Operation, Testing and Adjusting, “Air Inlet and Exhaust
System - Inspect” for additional information.

6. Turbocharger Turbocharger Result: There is a fault on the turbocharger.

A. Ensure that the mounting bolts for the turbocharger are tight. Repair: Repair the turbocharger or replace the turbo-
charger. Refer to Disassembly and Assembly, “Turbo-
B. Check that the oil drain for the turbocharger is not blocked or charger - Remove” and Disassembly and Assembly,
restricted. “Turbocharger - Install”.

C. Check that the compressor housing for the turbocharger is free If the turbocharger is replaced, use the electronic service
of dirt and debris. Make sure that the housing is not damaged. tool to perform the “Turbocharger Wastegate Actuator Re-
placement Reset” .
D. Check that the turbine housing for the turbocharger is free of Use the electronic service tool to perform the “Air System
dirt and debris. Make sure that the housing is not damaged. Motor Valve Verification Test”
Result: The “Air System Motor Valve Verification Test”
E. Check that the turbine blades rotate freely in the turbocharger. failed.

F. Use the electronic service tool to perform the “Air System Motor Repair: Troubleshoot any diagnostic codes that were gen-
Valve Verification Test” . erated. Refer to Troubleshooting, Diagnostic Trouble
Codes.
Result: The turbocharger is OK. The “Air System Motor
Valve Verification Test” passed.

Proceed to Test Step 7.

(continued)

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 M0095947-10 39
Symptom Troubleshooting

(Table 4, contd)

7. Check the Fuel System Fuel system Result: The fuel pressure is OK.

Refer to Systems Operation, Testing and Adjusting, “Fuel Sys- Proceed to Test Step 8.
tem” for additional information.
Result: The fuel pressure is not OK.
A. Visually check the fuel level in the fuel tank. Do not rely on the
fuel gauge only. Repair: Replace the fuel filters. Clean the primary filter/
water separator of debris. Refer to the Operation and
B. Ensure that the vent in the fuel cap is not filled with debris. Maintenance Manual for details.

C. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position.

D. Inspect the fuel system. Refer to Systems Operation, Testing

and Adjusting, “Fuel System - Inspect” for additional information.

E. Cold weather adversely affects the characteristics of the fuel.

Refer to the engines Operation and Maintenance Manual for in-
formation on improving the characteristics of the fuel during cold-
weather operation. Cold mode (if applicable) is activated when-
ever the engine coolant temperature falls below a predetermined
value. Monitor the status screen on the electronic service tool to
verify that the engine has exited cold mode. Observe the reading
for coolant temperature on the electronic service tool.

Refer to "Cold Mode Operation" within Systems Operation,

Testing and Adjusting, “General Information”.

F. Check the fuel quality. Refer to Systems Operation, Testing

and Adjusting, “Fuel Quality - Test” for the proper procedure.
Check the fuel tank for debris or foreign objects which may block
the fuel supply.

G. Check for the proper operation of the fuel transfer pump. Refer
to Systems Operation/Testing and Adjusting, “Fuel System” for
test information.

Engine loads Result: There is not a parasitic load.

8. Engine Load
Proceed to Test Step 9.
A. Check accessories and parasitic loads on the engine.
Result: There is a parasitic load.

Repair: Remove the parasitic load.

9. Valve Lash Valve lash Result: The valve lash is not correct.

Note: The valve lash can affect the performance of the engine. Repair: Check the valve lash. Refer to Systems Opera-
A. Check the valve lash. tion, Testing, and Adjusting, “Engine Valve Lash - Inspect”
for the correct procedure.

Result: The valve lash is correct.

Proceed to Test Step 10.

(continued)

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 40 M0095947-10
Symptom Troubleshooting

(Table 4, contd)

10. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside
compression the specifications.
A. Perform a compression test. Refer to Systems Operation,
Testing, and Adjusting, “Compression - Test”. Repair: Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown in

the following list:

· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Result: The results of the compression test are OK.

Proceed to Test Step 11.

11. Electronic Unit Injectors Electronic Unit Result: A faulty injector is indicated.
Injectors
A. Use the electronic service tool to perform the automatic “Cylin- Repair: Remove any faulty electronic unit injectors. Refer
der Cutout Test” . Refer to Troubleshooting, Service Tool Fea- to Disassembly and Assembly, “Electronic Unit Injector -
tures for more information on understanding the results of the Remove”.
“Cylinder Cutout Test” .
Install new electronic unit injectors. Refer to Disassembly
Note: If the compression test that was performed in Test Step 9 and Assembly, “Electronic Unit Injector - Install”.
was satisfactory, the “Cylinder Cutout Test” will identify any faulty
injectors. Repeat the automatic “Cylinder Cutout Test” . If the fault is
still apparent, remove the replacement electronic unit in-
jector and install the original electronic unit injector. Refer
to Disassembly and Assembly, “Electronic Unit Injector -
Remove” and Disassembly and Assembly, “Electronic Unit
Injector - Install”.

Result: All injectors are OK.

Proceed to Test Step 12.

12. Individual Malfunctioning Cylinders Cylinders Result: The test indicates a faulty cylinder.

A. With the engine speed at a fast idle, use the electronic service Repair: Investigate the cause of the fault on any cylinder
tool to perform the manual “Cylinder Cutout Test” . that is not operating. Investigate the cause of the fault on
any cylinder that is operating below normal performance.
As each cylinder is cut out, listen for a change in the sound from
the engine. When a cylinder is cut out, there should be a notice- Result: The test indicates that all cylinders are OK.
able change in the sound of the engine.
Contact the Dealer Solutions Network (DSN).
If a change in the sound of the engine is not noted, the isolated
cylinder is not operating under normal conditions. If the isolation
of a cylinder results in a change in the sound that is less notice-
able, the cylinder may be operating below normal performance.

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 M0095947-10 41
Symptom Troubleshooting

i06151955

Alternator Problem
(Charging Problem and/or Noisy
Operation)

Probable Causes
• Alternator drive belt and tensioner

• Alternator mounting bracket

• Alternator drive pulley
• Alternator bearings

• Alternator
• Charging circuit

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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 42 M0095947-10
Symptom Troubleshooting

Table 5
Troubleshooting Test Steps Values Results

1. Condition of the Alternator Drive Belts Drive Belt Result: The alternator drive belts are in good condition and
the belt tension is correct.
A. Inspect the condition of the alternator drive belts.
Proceed to Test Step 2.
B. Check the belt tension. If the engine is equipped with an
automatic belt tensioner, check the automatic belt tensioner. Result: The alternator drive belts are not in good condition
or the belt tension is incorrect.
Excessive belt tension can result in damage to the alternator.
Repair: If the alternator drive belts are worn or damaged,
replace the belts. Refer to Disassembly and Assembly for
the correct procedure.

If necessary, replace the automatic belt tensioner. Refer to

Disassembly and Assembly for the correct procedure.

2. Alternator Mounting Bracket Alternator Mount- Result: The alternator mounting bracket is cracked and
ing Bracket distorted.
A. Inspect the alternator mounting bracket for cracks and
distortion. Repair the mounting bracket or replace the mounting
bracket.

Note: The repair/replacement will ensure that the alterna-

tor drive belt and the alternator drive pulley are in
alignment.

Result: The alternator mounting bracket is OK.

Proceed to Test Step 3.

3. Condition of the Alternator Drive Pulley Alternator Drive Result: There is excessive wear on the alternator drive
Pulley pulley.
A. Check the condition of the alternator drive pulley. Look for
deep grooves that have been worn into the pulley by the belt. Repair: Replace the pulley.
Check that the nut for the pulley has not become loose.
Result: The alternator drive pulley nut was loose.

Repair: Tighten the nut.

Result: There is not excessive wear on the alternator drive

pulley.

Proceed to Test Step 4.

4. Wear of the Alternator Bearings Alternator Bearings Result: The alternator bearings are OK.

A. Check the alternator bearings for signs of wear. Proceed to Test Step 5.

Result: The alternator bearings are not OK.

Repair: Repair the alternator or replace the alternator, as

needed. Refer to Disassembly and Assembly for the cor-
rect procedure.

(continued)

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 M0095947-10 43
Symptom Troubleshooting

(Table 5, contd)
Troubleshooting Test Steps Values Results

5. Operation of the Alternator or Regulator Regulator and Result: The regulator and alternator are operating
Alternator correctly.
A. Verify that the alternator or the regulator is operating cor-
rectly. Refer to Systems Operation, Testing and Adjusting, Proceed to Test Step 6.
“Charging System - Test” for the proper testing procedures.
Result: The regulator and alternator are not operating
correctly.

Repair: Repair the alternator and regulator or replace the

alternator and regulator, as needed. Refer to Disassembly
and Assembly for the correct procedure.

6. Inspection of the Charging Circuit Charging Circuit Result: The charging circuit is not working correctly.

A. Inspect the battery cables, wiring, and connections in the Repair: Clean all connections and tighten all connections.
charging circuit. Replace any faulty parts.

Result: The charging circuit is working correctly.

Contact the Dealer Solutions Network (DSN).

i07708815

Battery Problem

This procedure covers the following diagnostic code:

Table 6
Diagnostic Trouble Code for Battery Problem

J1939 Description Notes

Code
168-31 Battery Potential / Power Input #1 The engine idle has been elevated to increase battery voltage.

This diagnostic code does not necessarily indicate a fault. This feature is used to in-
crease an excessively low battery voltage while the engine is at idle.

Probable Causes
• Charging circuit

• Batteries
• Auxiliary device

Recommended Actions
Complete the procedure in the order in which the
steps are listed.

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 44 M0095947-10
Symptom Troubleshooting

Table 7
Troubleshooting Test Steps Values Results

1. Charging Circuit Charging Result: The charging circuit is not OK.

circuit
A. Check that the battery charging circuit is operating correctly. Repair: Repair the charging circuit, as necessary.
Refer to Troubleshooting, “Alternator Problem”.
Result: The charging circuit is OK.

Proceed to Test Step 2.

2. Batteries Battery Result: One of the batteries is not OK.

A. Verify that the battery or batteries are no longer able to hold a Repair: Replace the faulty battery. Refer to the Operation
charge. Refer to Systems Operation/Testing and Adjusting, “Bat- and Maintenance Manual.
tery - Test”.
Result: The battery or batteries are OK.

Proceed to Test Step 3.

3. Auxiliary Device Auxiliary Result: The battery or batteries have been drained by an
Device auxiliary device being left in the ON position.
A. Check if an auxiliary device has drained the battery or batteries
by being left in the ON position. Repair: Charge the battery or batteries. Verify that the battery
or batteries are able to maintain a charge. Refer to Systems
Operation/Testing and Adjusting for the correct procedure.

Result: The battery or batteries have not been drained by an

auxiliary device being left in the ON position.

Contact the Dealer Solutions Network (DSN).

i07449212

Clean Emissions Module Has

High Oxygen Level

Table 8
Diagnostic Trouble Codes for CEM High Oxygen Level

J1939 Code Code Description Comments

Aftertreatment #1 Intake O2 : High - mod-
3217-16 The engine out NOx Sensor is reading high O2
erate severity (2)

Aftertreatment #1 Outlet O2 : High - mod-

3227-16 The tailpipe out NOx Sensor is reading high O2
erate severity (2)

Follow the troubleshooting procedure to identify the root cause of the fault.

The engine out NOx sensor is located between the

Diesel Particulate Filter (DPF) and the Selective
Catalytic Reduction (SCR) catalyst, before the Diesel
Exhaust Fluid (DEF) injector. The tailpipe out NOx
sensor is located in the exhaust tail pipe.
Complete the procedure in the order in which the
steps are listed.

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 M0095947-10 45
Symptom Troubleshooting

Table 9
Troubleshooting Test Steps Values Results
Correctly In-
1. Check the Installation of the NOx Sensors stalled / Not in- Result: The sensor is not installed correctly.
stalled correctly
A. Locate the appropriate NOx Sensor. Repair: Install the sensor correctly.

B. Check if the sensor is installed correctly. Proceed to Test Step 3.

Result: The sensor is installed correctly.

Proceed to Test Step 2.

2. Check for an Exhaust Leak Between the Turbocharger and Leak found Result: An exhaust leak is found between the turbo and
the Tailpipe the tail pipe.

A. Check for disconnected exhaust lines. Repair: Repair the exhaust leak.

B. Check for broken/loose joints. Proceed to Test Step 3.

Test passed
3. Perform the Aftertreatment System Functional Test Result: The Aftertreatment System Functional Test
passed.
A. Reset all active codes and clear all logged codes.
The NOx Sensing system is fully functional and the fault
B. Use the electronic service tool to perform the “Aftertreatment has been eliminated.
System Functional Test” to verify that the fault is eliminated.
Return the unit to service.

Result: The Aftertreatment System Functional Test did

not pass and the diagnostic code is still present.

Repair: Replace the sensor.

If the fault is still present, contact the Dealer Solutions

Network (DSN).

i07704970

Coolant Contains Oil

Probable Causes
• Engine oil cooler
• Cylinder head gasket

• Cylinder head
• Cylinder block

Recommended Actions
Complete the procedure in the order in which the
steps are listed.

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 46 M0095947-10
Symptom Troubleshooting

Table 10
Troubleshooting Test Steps Values Results

1. Engine Oil Cooler Oil Cooler Result: A leak is found in the engine oil cooler.

A. Drain the coolant from the cooling system. Drain the lubri- Repair: Install a new oil cooler. Refer to Disassembly and
cating oil from the engine. Refer to the Operation and Mainte- Assembly, “Engine Oil Cooler - Remove” and Disassembly
nance Manual for more information. and Assembly, “Engine Oil Cooler - Install” for the correct
procedure.
B. Check for leaks in the engine oil cooler. Refer to Systems
Operation, Testing, and Adjusting, “Cooling System” for the Flush the cooling system. Refer to the Operation and
correct procedure. Maintenance Manual for the correct procedure. Refill the
cooling system with the correct coolant. Refer to the Oper-
ation and Maintenance Manual for the recommended
coolant and capacities.

After the leak has been repaired, refill the engine with oil
of the correct specification . Refer to the Operation and
Maintenance Manual for the correct oil capacity and
viscosity.

Result: A leak was not found in the engine oil cooler.

Proceed to Test Step 2.

2. Cylinder Head Gasket Cylinder head Result: The cylinder head gasket shows signs of damage
gasket or leakage.
A. Remove the cylinder head. Refer to Disassembly and As-
sembly, “Cylinder Head - Remove”. Repair: Install a new cylinder head gasket and install the
cylinder head. Refer to Disassembly and Assembly, “Cyl-
B. Inspect the cylinder head gasket for faults and any signs of inder Head - Install” .
leakage.
Result: The cylinder head gasket does not show signs of
damage or leakage.

Proceed to Test Step 3.

(continued)

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 M0095947-10 47
Symptom Troubleshooting

(Table 10, contd)

Troubleshooting Test Steps Values Results

3. Cylinder Head Cylinder head Result: A fault was found in the cylinder head.

A. Check for cracks in the cylinder head. Perform a leak test Repair: Repair the cylinder head or replace the cylinder
on the cylinder head. Refer to System Operation, Testing and head. Install the cylinder head. Refer to Disassembly and
Adjusting, “Cylinder Head - Inspect” for the correct procedure. Assembly, “Cylinder Head - Install”.

Refill the engine with oil of the correct specification . Refer

to the Operation and Maintenance Manual for the correct
oil capacity and viscosity.

Result: A fault was not found in the cylinder head.

Proceed to Test Step 4.

4. Cylinder Block Cylinder block Result: A fault was found in the cylinder block.

A. Inspect the top face of the cylinder block for faults and signs Repair: Repair the cylinder block or replace the cylinder
of leakage. block. Inspect the top deck. Refer to the Reuse and Sal-
Refer to Systems Operation, Testing, and Adjusting, “Cylinder vage Guidelines for the proper inspection procedure.
Block - Inspect” for the correct procedure.
Refill the engine with oil of the correct specification . Refer
to the Operation and Maintenance Manual for the correct
oil capacity and viscosity.

Result: No fault was found in the cylinder block.

Install the cylinder head. Refer to Disassembly and As-

sembly, “Cylinder Head - Install”.

Contact the Dealer Solutions Network (DSN).

i07708862

Coolant Level Is Low

This procedure is only applicable to engines that

have a coolant level sensor.
This procedure covers the following diagnostic code:
Table 11
Diagnostic Trouble Codes for Low Coolant Level

J1939 Code Code Description Comments

The engine has been running for 60 seconds. The engine coolant level has fallen
Engine Coolant Level : Low - most severe
111-1 below the coolant level sensor for the specified delay time.
(3)
Engine power is derated. The code is logged.

The engine has been running for 60 seconds. The engine coolant level has fallen
Engine Coolant Level : Low - least severe
111–17 below the coolant level sensor for the specified delay time.
(1)
Engine power is derated. The code is logged.

The engine has been running for 60 seconds. The engine coolant level has fallen
Engine Coolant Level : Low - moderate se-
111-18 below the coolant level sensor for the specified delay time.
verity (2)
Engine power is derated. The code is logged.

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 48 M0095947-10
Symptom Troubleshooting

Probable Causes
• Low Coolant Level and/or Coolant Leakage
• Coolant level sensor

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

Table 12
Troubleshooting Test Steps Values Results

1. Low Coolant Level and/or Coolant Leakage Coolant level Result: The engine coolant level is OK.

A. Inspect the coolant level. Proceed to Test Step 2.

Result: The engine coolant level is not OK.

Repair: Troubleshoot the cause of the incorrect coolant

level.

Check for the correct mixture of antifreeze and water. Refer

to Operation and Maintenance Manual.

Check the cooling system for leaks. Refer to Systems Oper-

ation, Testing and Adjusting, “Cooling System - Test” for the
correct procedure. Repair any leaks immediately.

Check the NRS cooler for leaks. Refer to Systems Opera-

tion, Testing and Adjusting, “Exhaust Cooler (NRS) - Test”.

Check for air in the cooling system. Refer to Systems Opera-

tion, Testing and Adjusting, “Testing the Cooling System” for
the correct procedure.

2. Faulty Sensor Coolant level Result: The coolant level sensor is not operating correctly.
sensor
A. If an electrical fault with the coolant level sensor is suspected, Repair: Replace the coolant level sensor.
refer to Troubleshooting, “Coolant Level - Test” for information on
troubleshooting the coolant level sensor. Result: The coolant level sensor is operating correctly.

Contact the Dealer Solutions Network (DSN).

i07482968

Coolant Temperature Is High

Use this procedure to troubleshoot high coolant

temperature or use this procedure if one of the
following event codes is active. Refer to
Troubleshooting, “Event Codes” for information about
event codes. Use the electronic service tool to view
the current trip points for these codes.

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 M0095947-10 49
Symptom Troubleshooting

Table 13
Diagnostic Trouble Codes for High Coolant Temperature

J1939 Code Code Description Comments

The engine coolant temperature has exceeded the trip point and the delay time
Engine Coolant Temperature : High - least se-
110-15 has expired.
vere (1)
The code is logged.

The engine coolant temperature has exceeded the trip point and the delay time
Engine Coolant Temperature : High - moder-
110-16 has expired.
ate severity (2)
The code is logged.

The engine coolant temperature has exceeded the trip point and the delay time
Engine Coolant Temperature : High - most
110-0 has expired.
severe (3)
The code is logged.

Probable Causes
• Diagnostic codes

• Coolant level
• Belt and belt tensioner

• Coolant temperature sensor

• Radiator and hoses

• Radiator cap and pressure relief valve

• Water temperature regulator
• Engine cooling fan

• Quality of coolant
• Coolant pump

• NRS cooler
• Cylinder head gasket

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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 50 M0095947-10
Symptom Troubleshooting

Table 14
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Diagnostic Result: Diagnostic codes are not present.

Codes
A. Use the electronic service tool to check for diagnostic codes Return the unit to service.
that relate to the temperature in the cooling system.
Result: Diagnostic codes are present.

Proceed to Test Step 2.

2. Coolant Level Engine coolant Result: The engine coolant level is low.
level
A. Check the coolant level. Repair: Check the cooling system for leaks. Refer to Sys-
tems Operation, Testing and Adjusting, “Cooling System”
for additional information. Repair any leaks immediately.

Result: The engine coolant level is OK.

Proceed to Test Step 3.

3. Condition of the Alternator Drive Belts Drive Belt Result: The belts are in good condition and the belt ten-
sion is correct.
A. Inspect the condition of the belts.
Proceed to Test Step 4.
B. Check the belt tension. If the engine is equipped with an auto-
matic belt tensioner, check the automatic belt tensioner. Result: The belts are not in good condition or the belt ten-
sion is incorrect.

Repair: If the belts are worn or damaged, replace the

belts. Refer to Disassembly and Assembly for the correct
procedure.

If necessary, replace the automatic belt tensioner. Refer

to Disassembly and Assembly for the correct procedure.

4. Coolant Temperature Sensor Coolant tem- Result: The temperature sensor is not accurate.
perature
A. Compare the reading for the coolant temperature on the elec- sensor Repair: Troubleshoot the circuit and the coolant tempera-
tronic service tool to the reading for the coolant temperature on a ture sensor. Refer to Troubleshooting, “Sensor Signal
calibrated test gauge. (Analog, Passive) - Test”.

Result: The temperature sensor is reading accurately.

Proceed to Test Step 5.

(continued)

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 M0095947-10 51
Symptom Troubleshooting

(Table 14, contd)

Troubleshooting Test Steps Values Results

5. Radiator and Hoses Radiator and Result: The radiator fins are blocked or damaged.
hoses
A. Check the radiator fins for dirt, debris, and/or damage. Repair: Remove any dirt and/or debris and straighten any
bent fins.
B. Check for collapsed hoses and/or other restrictions.
Result: The radiator has internal blockage.
C. Check the radiator for internal blockage.
Repair: Remove the blockage.
Ensure that the radiator size is sufficient. An undersized radiator
does not have enough area for the effective release of heat. An un- Result: The radiator fins are not damaged and the radia-
dersized radiator may cause the engine to run at a temperature tor does not have an internal blockage.
that is higher than normal. The normal temperature depends on
the ambient temperature. Proceed to Test Step 6.

6. Radiator Cap and Pressure Relief Valve Radiator cap Result: The pressure relief valve and/or the water tem-
perature regulator are not operating correctly.
A. Pressure-test the cooling system. Refer to Systems Operation,
Testing, and Adjusting, “Cooling System” for the correct Repair: Clean the components or replace the
procedure. components.

B. Check that the seating surfaces of the pressure relief valve and Result: The pressure relief valve and/or the water tem-
the radiator cap are clean and undamaged. perature regulator are operating correctly.

C. Check operation of the pressure relief valve and/or the water Proceed to Test Step 7.
temperature regulator.

7. Water Temperature Regulator Water Temper- Result: The water temperature regulator is not operating
ature Regulator correctly.
A. Check the water temperature regulator for correct operation.
Refer to Systems Operation, Testing, and Adjusting, “Cooling Sys- Repair: Replace the water temperature regulator. Refer
tem” for the proper procedure. to Disassembly and Assembly, “Water Temperature Regu-
lator - Remove and Install”.

Result: The water temperature regulator is operating

correctly.

Proceed to Test Step 8.

8. Engine Cooling Fan Fan Result: The cooling fan is not operating correctly.

A. Check that the cooling fan is operating correctly. Repair: Make sure that the cooling fan is being driven cor-
rectly. Make sure that the belt tensioner is operating
B. Check the engine cooling fan for damage. correctly

Result: The fan is damaged.

Repair: Repair the fan or replace the fan, as necessary.

Refer to Disassembly and Assembly, “Fan - Remove and
Install”.

Result: The fan is OK.

Proceed to Test Step 9.

(continued)

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Symptom Troubleshooting

(Table 14, contd)

Troubleshooting Test Steps Values Results

9. Quality of Coolant Coolant Result: The coolant is not of an acceptable quality.

A. Check the quality of the coolant. Refer to the Operation and Repair: Drain and refill the coolant system with coolant of
Maintenance Manual, “Refill Capacities and Recommendations - the correct quality. Refer to the Operation and Mainte-
Coolant”. nance Manual, “Refill Capacities and Recommendations -
Coolant”.

Result: The coolant is of an acceptable quality.

Proceed to Test Step 10.

10. Inspection of the Coolant Pump Coolant pump Result The coolant pump is damaged or not operating
correctly.
A. Inspect the impeller of the coolant pump for damage and/or
erosion. Repair: If necessary, replace the coolant pump. Refer to
Disassembly and Assembly, “Water Pump - Remove” and
B. Make sure that the fan belt is not loose on the drive pulley of the Disassembly and Assembly, “Water Pump - Install”.
coolant pump.
Result The coolant pump is not damaged and the pump
is operating correctly.

Proceed to Test Step 11.

11. NRS Cooler NRS cooler Result: The leak test fails.

A. Switch off the engine and allow the engine to cool to below nor- Repair: Check the NRS cooler. Perform a leak test on the
mal working temperature. Remove the pressure cap for the cool- NRS cooler. Refer to Systems Operation, Testing, and Ad-
ant system. Perform a leak test on the cooling system and the justing, “Exhaust Cooler (NRS) - Test”.
NRS cooler. Refer to Systems Operation, Testing, and Adjusting,
“Cooling System - Test”. Refer to the subsection “Testing The Ra- If necessary, install a replacement NRS cooler. Confirm
diator And Cooling System For Leaks” . that the fault has been eliminated.

Result: The leak test is passed.

Proceed to Test Step 12.

12. Cylinder Head Gasket Cylinder Head Result: The leak test fails.
gasket
A. Switch off the engine and allow the engine to cool to below nor- Repair: Check the cylinder head gasket. Refer to the rec-
mal working temperature. Remove the pressure cap for the cool- ommended action for the cylinder head gasket within
ant system. Perform a leak test on the cooling system and the Troubleshooting, “Oil Contains Coolant”.
NRS cooler. Refer to Systems Operation, Testing, and Adjusting,
“Cooling System - Test”. Refer to the subsection “Testing The Ra- Check the cylinder head for flatness. Refer to the recom-
diator And Cooling System For Leaks” . mended action for checking flatness of the cylinder head
within Systems Operation, Testing, and Adjusting, “Cylin-
der Head - Inspect”.

Result: The leak test is passed.

Contact the Dealer Solutions Network (DSN).

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 M0095947-10 53
Symptom Troubleshooting

i07486429

Coolant Temperature Is Low

Use this procedure to troubleshoot a low coolant

temperature.

Probable Causes
• Extreme ambient temperatures

• Cooling system fault

• Coolant temperature sensor

• Water temperature regulator

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

Personal injury can result from hot coolant,

steam and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
Cooling System Conditioner contains alkali.
Avoid contact with skin and eyes.

Table 15
Troubleshooting Test Steps Values Results

1. Make Sure the Engine is Correctly Equipped for Ambient Engine operation Result: The engine is equipped for the ambient
Conditions conditions.

A. Ensure that the engine is correctly equipped for the ambient Proceed to Test Step 2.
conditions.
Result: The engine is not equipped for ambient
conditions.

Repair: Refer to the Operation and Maintenance Man-

ual for more information regarding equipment required
for cold-weather operation.

(continued)

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 54 M0095947-10
Symptom Troubleshooting

(Table 15, contd)

2. Inspect the Cooling System Engine coolant Result: The engine coolant level is OK.
level
A. Check the coolant level. Proceed to Test Step 3.

B. Check for signs of a coolant leak. Result: The engine coolant level is not OK.

Note: If the coolant temperature sensor is not immersed in coolant, Repair: Check the cooling system for leaks. Refer to
a false reading can occur. Troubleshooting, “Coolant Level is Low” for additional
information. Repair any leaks.

3. Faulty Coolant Temperature Sensor Faulty coolant Result The coolant temperature is as expected.
temperature
A. Check the reading of the coolant temperature on the electronic sensor Repair: A failed coolant temperature sensor has been
service tool. The temperature should rise steadily as the engine is detected. Replace the temperature sensor.
warmed. Ensure that the temperature is as expected.
Result The coolant temperature is as expected.

Proceed to Test Step 4.

4. Check the Engine Coolant System Coolant Result: The coolant temperature comes up to opera-
temperature tional temperature.
A. Turn the keyswitch to the OFF position.
Return the unit to service.
B. Connect to the electronic service tool.
Result The coolant temperature does not come up to
C. Start the engine. operational levels.

D. Monitor the “Engine Coolant Temperature” in the status screen Repair: Test the water temperature regulator. Refer to
Systems Operation, Testing, and Adjusting, “Water
Temperature Regulator - Test”. If the test fails, replace
the water temperature regulator. Refer to Disassembly
and Assembly, “Water Temperature Regulator - Re-
move and Install”.

If the fault is still present, contact the Dealer Solutions

Network (DSN).

i07488278 Recommended Actions

Cylinder Is Noisy Note: The procedures have been listed in order of
probability. Complete the procedures in order.

Probable Causes
• Diagnostic codes

• Fuel quality
• Valve train components

• Low compression (cylinder pressure)

• Injectors

• Pistons and connecting rods

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 M0095947-10 55
Symptom Troubleshooting

Table 16
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Codes Result: A diagnostic trouble code is active or logged.

A. Establish communication between the electronic service tool Repair: Troubleshoot the active or logged codes.
and the Electronic Control Module (ECM).
Result: A diagnostic trouble code is not active or logged.
B. Use the electronic service tool to check for active or logged
codes. Proceed to Test Step 2.

2. Fuel Quality Fuel Result: The fuel quality is not OK.

A. Check the fuel quality. Refer to Systems Operation, Testing, and Repair: Drain the fuel system and replace the fuel filters.
Adjusting, “Fuel Quality - Test”. Refer to Operation and Maintenance Manual, “Fuel Sys-
tem Primary Filter (Water Separator) Element - Replace”
B. Refer to Operation and Maintenance Manual for information on and Operation and Maintenance Manual, “Fuel System Fil-
the correct characteristics of the fuel for the engine. ter - Replace”.

Fill the fuel system with fuel that meets the standard in the
Operation and Maintenance Manual, “Fluid
Recommendations”.

Prime the fuel system. Refer to the Operation and Mainte-

nance Manual, “Fuel System - Prime”.

Verify that the procedure has eliminated the noise.

Result: The fuel quality is OK.

Proceed to Test Step 3.

3. Valve Train Components Valve train Result: Valve train components are damaged.

A. Check the valve lash. Refer to Troubleshooting, “Valve Lash Is Repair: Make the necessary repairs, Verify that the repair
Excessive”. has eliminated the noise.

B. Check for damage to valve train components. Remove the valve Result: The valve train components are not damaged.
cover from the engine. Check the following items for damage:
Proceed to Test Step 4.
· Valve springs

· Rocker shaft

· Bridges

· Pushrods

· Camshaft followers

· Hydraulic lifters

Refer to Disassembly and Assembly for additional information.

(continued)

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 56 M0095947-10
Symptom Troubleshooting

(Table 16, contd)

Troubleshooting Test Steps Values Results

4. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside
compression the specifications.
A. Perform a compression test. Refer to Systems Operation, Test-
ing, and Adjusting, “Compression - Test”. Repair: Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown in

the following list:

· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Result: The results of the compression test are OK.

Proceed to Test Step 5.

5. Electronic Unit Injectors Electronic Unit Result: A faulty injector is indicated.

Injectors
A. Use the electronic service tool to perform the automatic “Cylin- Repair: Remove any faulty electronic unit injectors. Refer
der Cutout Test” . Refer to Troubleshooting, Service Tool Features to Disassembly and Assembly, “Electronic Unit Injector -
for more information on understanding the results of the “Cylinder Remove”.
Cutout Test” .
Install new electronic unit injectors. Refer to Disassembly
Note: If the compression test that was performed in Test Step 4 and Assembly, “Electronic Unit Injector - Install”.
was satisfactory, the “Cylinder Cutout Test” will identify any faulty
injectors. Repeat the automatic “Cylinder Cutout Test” . If the fault is
still apparent, remove the replacement electronic unit injec-
tor and install the original electronic unit injector. Refer to
Disassembly and Assembly, “Electronic Unit Injector - Re-
move” and Disassembly and Assembly, “Electronic Unit In-
jector - Install”.

Result: All injectors are OK.

Proceed to Test Step 6.

6. Pistons and Connecting Rods Pistons Result: One or more components are worn or damaged.

A. Inspect the pistons for damage and wear. Repair: Replace any worn or damaged parts.

B. Inspect the connecting rod bearings for damage and wear. Verify that the repair has eliminated the noise.

Result: All components are OK.

If the fault is still present, contact the Dealer Solutions Net-

work (DSN).

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 M0095947-10 57
Symptom Troubleshooting

i07636386

DEF Does Not Purge

Table 17
Diagnostic Trouble Codes for DEF Does Not Purge

J1939 Code Description Comments

Code
Aftertreatment #1 DEF Dosing Unit The DEF system did not completely purge after the engine was turned OFF.
3362-14
Input Lines : Special Instruction The code is logged.

NOTICE
Wait 2 minutes after the engine has stopped before
turning the battery disconnect switch to the OFF posi-
tion. The DEF system requires 2 minutes to purge
diesel exhaust fluid (DEF) from system components
automatically. Failing to complete the purge could
damage the SCR system.

Table 18
Associated Codes
J1939 Code
4334-16
4374-5
4374-6
4376-5
4376-6

Complete the procedure in the order in which the

steps are listed.

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Table 19
Troubleshooting Test Steps Values Results

1. Review the “ Aftertreatment Abnormal Shutdown History”” DEF Pump Result: The system was not allowed 2 minutes to purge
before the battery disconnect was turned to the OFF
A. Connect to the ECM using the electronic service tool. position.

B. Proceed to “Aftertreatment Abnormal Shutdown History” . Se- Inform the operator to wait 2 minutes after key-off before
lect the “Information” tab, then select the “History” tab in the elec- turning the battery disconnect to the OFF position.
tronic service tool menu. Return the unit to service.

C. Review the engine shutdown type for cold shutdown Result: The system was allowed 2 minutes to purge be-
occurrences. fore the battery disconnect was turned to the OFF
position.

Proceed to Test Step 2.

2. Check for Associated Diagnostic Trouble Codes Diagnostic trou- Result: An associated diagnostic trouble code is
ble code present.
A. Connect to the ECM using the electronic service tool.
Repair: Troubleshoot the associated code. Refer to Trou-
B. Check for associated diagnostic trouble codes. bleshooting, “Diagnostic Trouble Codes”.

Result: An associated diagnostic trouble code is not

present.

Contact the Dealer Solutions Network (DSN).

i07622682

DEF Module Does Not

Respond

Use this procedure to troubleshoot the following

codes:
Note: Refer to Troubleshooting, “Service Tool
Features” for more information about service
features.
Table 20
Diagnostic Trouble Codes for DEF Module Does Not Respond

J1939 Code Code Description Comments

Aftertreatment #1 DEF Dosing Unit : Not Re-
3361-7 The DEF injector is not functioning properly.
sponding Properly

Table 21 Note: The procedures have been listed in order of

Required Tools probability. Complete the procedure in the order in
which the steps are listed.
Tool Part Number Part Description Qty

A T400241 Probe - Female 2

B T400240 Probe - Male 2

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 M0095947-10 59
Symptom Troubleshooting

Table 22
Troubleshooting Test Steps Values Results

1. Check the Resistance of the DEF Injector 10 Ohms to 20 Result : The resistance of the DEF injector measured be-
Ohms tween 10 Ohms and 20 Ohms.
A. Turn the keyswitch to the OFF position. Allow 2 minutes to
elapse before proceeding. Proceed to Test Step 2.

B. Disconnect the DEF injector from the applicable harness. Result : The resistance of the DEF injector did not meas-
ure between 10 Ohms and 20 Ohms. A failed DEF injec-
C. Inspect the connector for damage or debris. tor has been detected.

D. Connect Tooling A to the DEF injector. The probes must be Repair : Replace the failed DEF injector. Refer to the Dis-
used to prevent damage to the DEF injector connector. assembly and Assembly, “DEF Injector and Mounting -
Remove and Install”.
E. Measure the resistance of the DEF injector.
Proceed to Test Step 8.

2. Check for a Short Circuit in the Wiring Harness. Greater than Result : The resistance of the DEF injector wiring har-
10K Ohms ness measured greater than 10K Ohms.
A. Turn the keyswitch to the OFF position. Allow 2 minutes to
elapse before proceeding. Repair : Connect the injector to the applicable harness.

B. Disconnect the injector from the applicable harness Proceed to Test Step 3.

C. Connect Tooling B to the DEF injector harness connector. The Result : The resistance of the DEF injector wiring har-
probes must be used to prevent damage to the connector. ness did not measure greater than 10K Ohms.

D. Measure the resistance between the two probes. Repair : There is a short circuit in the wiring harness be-
tween the DEF injector connector and the DCU. Repair or
Note : The reading will measure the resistance in the wiring har- replace the wiring harness. Connect the injector to the ap-
ness between the DEF injector connector and the ECM. plicable harness.

Proceed to Test Step 8.

3. Check the Diesel Exhaust Fluid (DEF) Quality. DEF Result : The DEF is not contaminated and the concentra-
tion is within the acceptable range.
A. Measure the DEF quality. Refer to Systems Operation, Testing
and Adjusting, “Diesel Exhaust fluid Quality - Test” for the correct Proceed to Test Step 4.
procedure.
Result : The DEF is not contaminated but the concentra-
tion is not within the acceptable range.

Repair : Drain the DEF from the tank. Refill the tank with
DEF that meets ISO 22241 quality standards.

Proceed to Test Step 8.

Result : The DEF is contaminated.

Repair : Contact the Dealer Solutions Network (DSN) for

further information.

(continued)

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Symptom Troubleshooting

(Table 22, contd)

Troubleshooting Test Steps Values Results

4. Perform the “ DEF Dosing System Accuracy Test”” DEF dosing sys- Result : The quantity collected is below specification.
tem accuracy
A. Use the electronic service tool to perform the “DEF Dosing Sys- test Proceed to Test Step 5.
tem Accuracy Test” . Refer to Systems Operation, Testing and Ad-
justing, “Aftertreatment SCR System Dosing - Test” for the correct Result : The quantity collected is within the desired
procedure. range. The desired range is 100 mL (3.4 oz) minimum to
130 mL (4.4 oz) maximum.

Proceed to Test Step 9.

Result : The quantity collected is above specification.

Repair : A failed DEF injector has been detected, replace

the failed DEF injector. Refer to the Disassembly and As-
sembly, “DEF Injector and Mounting - Remove and
Install”.

Proceed to Test Step 7.

5. Check the DEF Pressure Line Restriction, ob- Result : There are restrictions or leaks in the lines.
structions, and
A. Turn the keyswitch to the OFF position. Allow 2 minutes to leaks Repair : Flush or replace the line.
elapse before proceeding.
Proceed to Test Step 7.
B. Visually inspect the lines for leaks or damage.
Result : An obstruction was not found and the line was
C. Remove the DEF pressure line between the DEF pump and not damaged.
the DEF injector. Refer to Disassembly and Assembly, “Diesel Ex-
haust Fluid Lines - Remove and Install” for the correct procedure. Proceed to Test Step 6.

D. Inspect the DEF pressure line for obstructions. Flush the line
with water or low-pressure air, if necessary.

Note : Possible obstructions are ice, DEF deposits, or debris.

6. Replace the DEF Injector DEF injector

Result: The DEF injector was connected to the DEF
A. Turn the keyswitch to the OFF position. pressure line and the electrical connector.

B. Remove the DEF injector. Refer to Disassembly and Assembly, Proceed to Test Step 7.
“DEF Injector and Mounting - Remove and Install”.
C. Connect the new DEF injector to the DEF pressure line and the
electrical connector.

Note: Do not install the new injector until Test Step 7 has been
completed.

(continued)

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 M0095947-10 61
Symptom Troubleshooting

(Table 22, contd)

Troubleshooting Test Steps Values Results

7. Perform the DEF Dosing System Accuracy Test DEF dosing sys- Result: The quantity collected is within specification.
tem accuracy
A. Use the electronic service tool to perform a “DEF Dosing Sys- test Install the new DEF injector. Refer to Disassembly and
tem Accuracy Test” . Refer to Systems Operation, Testing and Ad- Assembly, DEF Injector and Mounting Remove and
justing, “Aftertreatment SCR System Dosing Test” for the correct Install.
procedure.
Proceed to Test Step 8.

Result: The quantity collected is not within specification.

Repair : Replace the DEF pump. Refer to the Disassem-

bly and Assembly manual for the correct procedure.

Install the new DEF injector. Refer to Disassembly and

Assembly, DEF Injector and Mounting Remove and
Install.

Proceed to Test Step 8.

8. Perform the Aftertreatment Recovery Procedure Aftertreatment Result: The Aftertreatment Recovery Procedure com-
Recovery pleted successfully.
A. Connect to the electronic service tool. Procedure
Proceed to Test Step 9.
B. Perform the “Aftertreatment Recovery Procedure” .
Result: The Aftertreatment Recovery Procedure was not
successful.

Contact the Dealer Solutions Network (DSN).

9. Perform an “ Aftertreatment System Functional Test”” Electronic serv- Result : The test was successful.
ice tool test
A. Turn the keyswitch to the ON position. Return the unit to service.

B. Use the electronic service tool to perform an “Aftertreatment Result : The test not was successful and additional co-
System Functional Test” . des were logged.

C. Refer to “Aftertreatment Abnormal Shutdown History” under Repair : Troubleshoot the additional codes, refer to Trou-
the “Information” tab in the “Engine #1 Aftertreatment Controller” . bleshooting, Diagnostic Trouble Codes for the correct
procedure.
Note : If hot shutdowns have occurred, allow the engine to cool
down before shutting the machine OFF. Result: The test was not successful. No additional codes
were generated.

Contact the Dealer Solutions Network (DSN).

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 62 M0095947-10
Symptom Troubleshooting

i07488300

DEF Pressure Is High

Table 23
Diagnostic Trouble Codes for Diesel Exhaust Fluid (DEF) Pressure Is High

J1939 Code Code Description Comments

Aftertreatment #1 DEF #1 Pressure

4334–15
(absolute) : High - least severe (1)

The Electronic Control Module (ECM) detects that the DEF pump pressure is above the
acceptable range.
The code is logged.

Aftertreatment #1 DEF #1 Pressure

4334-16 (absolute) : High - moderate se-
verity (2)

Follow the troubleshooting procedure to identify the root cause of the fault.

Illustration 13 g06335376
Typical view of the DEF tank header
(1) Suction connector at the DEF tank header
(2) Backflow line connection at the DEF tank header

Illustration 14 g06335414
Typical view of the DEF pump
(3) Suction line connector at the DEF pump
(4) Backflow line connection at the DEF Pump

Complete the procedure in the order in which the

steps are listed.

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 M0095947-10 63
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Table 24
Troubleshooting Test Steps Values Results

1. Check the DEF Lines for a Restriction DEF line Result: An obstruction was found.
restriction
A. Turn the keyswitch to the OFF position. Allow 2 minutes to Repair: If the line is blocked, flush line with water/low
elapse before proceeding. pressure air. If the line is trapped, reroute the line. If nec-
essary, replace the line.
B. Remove the backflow line from DEF tank header (2) and DEF
pump (4). Proceed to Test Step 4.

C. Remove the suction line from the DEF tank header (1) and the Result: An obstruction was not found.
DEF pump (3).
Proceed to Test Step 2.
D. Inspect the removed lines for obstructions.

Note: Possible obstructions are ice, DEF deposits, debris, or a

trapped line.

2. Replace the Pressure and Backflow Fittings Replace Back- Result: The fittings were replaced.
flow Fitting
A. Replace the pressure and backflow fittings on the DEF pump. Proceed to Test Step 3.
Refer to Disassembly and Assembly, “Diesel Exhaust Fluid Pump
- Remove and Install” for the correct procedure.

3. Check for a Restriction in the DEF Pump DEF pump Result: DEF did not flow from the DEF backflow line into
restriction the container.
A. Connect the pressure line to DEF pump (3) and the DEF
injector. Repair: Replace the DEF pump. Refer to Disassembly
and Assembly, “Diesel Exhaust Fluid Pump - Remove
B. Connect the backflow line to DEF pump (2). Place the other and Install” for the correct procedure.
end of the line into a suitable container to collect the DEF.
Proceed to Test Step 4.
C. Turn the keyswitch to the ON position. Do not start the engine.
Result: DEF flowed from the backflow line into the
D. Connect to the electronic service tool. container.

E. Perform the “DEF Dosing System Verification Test” . Refer to Repair: Connect the backflow line to DEF tank header
Systems Operation, Testing, and Adjusting, “Aftertreatment SCR (1).
System Dosing Test”. Wait for the test to complete.
Proceed to Test Step 4.

4. Perform a “ Aftertreatment System Functional Test”” Diagnostic code Result: The test was successful.

A. Start the engine. Return the unit to service.

B. Connect to the electronic service tool. Result: The test was not successful. There are more ac-
tive diagnostic codes.
C. Perform the “Aftertreatment System Functional Test” .
Repair: Troubleshoot the additional codes. Refer to Trou-
bleshooting, “Diagnostic Trouble Codes”. Repeat Test
Step 4.

Result: The test was not successful. There are no addi-

tional codes.

Contact the Dealer Solutions Network (DSN).

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 64 M0095947-10
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i08139368

DEF Pressure Is Low

Table 25
Diagnostic Trouble Codes for Diesel Exhaust Fluid (DEF) Pressure Is Low

J1939 Code Code Description Comments

Aftertreatment #1 DEF #1 Pressure (abso- DEF pump pressure is not stable after the initial priming sequence
lute) : Not Responding Properly OR
4334-7
The DEF pump is not able to supply DEF after the line heaters have
been energized and a heating cycle has been completed

Aftertreatment #1 DEF #1 Pressure (abso- DEF system pressure dropped below the acceptable threshold during
4334-18
lute) : Low - moderate severity (2) dosing

Aftertreatment #1 DEF Dosing Unit #1

5392-31 DEF system pressure was not achieved during priming
Loss of Prime

Table 26
Troubleshooting Test Steps Values Results

1. Check the DEF tank filler cap DEF filler cap Result : A blockage was not found.

A. Clean dirt and debris from around the tank cap before remov- Proceed to Test Step 2.
ing the cap. Blockages can be caused by a build-up of dirt and
debris around the cap. Result : A blockage was found.

Note : A blocked DEF filler cap can cause a 5392-31 or E1370 Repair : Rinse the cap gently with clean water or replace
(2) code. the cap.

B. Remove and inspect the filler cap for blockages. Note: The cap contains a membrane so care must be tak-
en not to damage the membrane. If the cap cannot be
cleaned, the cap must be replaced.

Proceed to Test Step 2.

2. Check the DEF Gauge DEF gauge Result : The gauge did not move by adding or removing
DEF from the tank.
A. Turn the keyswitch to the ON position. Do not start the
engine. Proceed to Test Step 3.

B. Check the current position of the DEF gauge. Result : The gauge moved by adding or removing DEF
from the tank.
C. Turn the keyswitch to the OFF position.
Proceed to Test Step 4.
D. Clean dirt and debris from around the tank cap before remov-
ing the cap. Add or remove DEF from the DEF tank.

Note : Only use DEF that meets ISO 22241 quality standards.

E. Turn the keyswitch to the ON position. Do not start the

engine.

F. Check for a change in the DEF gauge position.

(continued)

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 M0095947-10 65
Symptom Troubleshooting

(Table 26, contd)

Troubleshooting Test Steps Values Results

3. Check the Electrical Connection at the DEF Tank Header Electrical Result : The electrical connections are free of corrosion
connections and loose wires.
A. Turn the keyswitch to the OFF position.
Repair : Replace the DEF tank header. Refer to the Disas-
B. Inspect the electrical connections to the DEF tank header. sembly and Assembly manual for the correct procedure.
Refer to Troubleshooting, “Electrical Connectors - Inspect” for
further information. Proceed to Test Step 11.

C. Inspect the connections for corrosion or loose wires. Result : The electrical connections are not free of corro-
sion or loose wires.

Repair : Make the necessary repairs.

Proceed to Test Step 12.

4. Check for Correct Installation of the DEF Lines DEF lines Result: The DEF lines are installed the wrong way round.

A. Check that the DEF lines are installed to the correct connec- Repair: Install the DEF lines to the correct connectors.
tors on the DEF pump.
Result: The DEF lines are installed correctly.

Proceed to Test Step 5.

5. Inspect the DEF Lines for Leaks DEF lines Result: A leaking or disconnected line was found.

A. Turn the keyswitch to the ON position. Do not start the Repair : Repair or replace the failed DEF line.
engine.
Proceed to Test Step 12.
B. Connect to the ECM using the electronic service tool.
Result: A leaking or disconnected line was not found.
C. Navigate to “Diagnostics Tests” .
Proceed to Test Step 6.
D. Perform the “DEF Dosing System Verification Test” to pres-
surize the system.

Note: This test may take up to 30 minutes to complete.

E. Inspect all DEF lines from the tank to the DEF injector. Check
for pinched, damaged, disconnected, or leaking lines.

6. Check the DEF Quality DEF Result : The DEF is not contaminated.

A. Measure the DEF quality. Refer to Testing and Adjusting, Proceed to Test Step 7.
“Diesel Exhaust Fluid Quality - Test” for the correct procedure.
Result : The DEF is contaminated.

Repair : Contact the Dealer Solutions Network (DSN) for

further information.

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 66 M0095947-10
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Illustration 15 g06337118
(1) DEF suction line connection on the header unit

Illustration 16 g03763616
(2) DEF suction line filter fitting
(3) DEF pump
(4) DEF pump filter cap

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 M0095947-10 67
Symptom Troubleshooting

Table 27
Troubleshooting Test Steps Values Results

7. Check for Suction Line Restrictions Restrictions Result: An obstruction or damage was found.

A. Disconnect the suction line from the DEF tank header and DEF Repair : Flush the line with water or low-pressure air or re-
pump. place the suction line.

B. Inspect the suction line for obstructions or damage. Also, check Proceed to Test Step 12.
that the line is connected in the proper locations.
Result: An obstruction or damage was not found.
Note : Possible obstructions are ice, DEF deposits, or debris.
Repair : Reinstall the suction line.

Proceed to Test Step 8.

8. Check for Return Line Restrictions Restrictions Result: An obstruction or damage was found.

A. Disconnect the return line from the DEF manifold and DEF Repair : Flush the line or connector with water or low-pres-
pump. sure air or replace the return line or return line fitting.

B. Inspect the return line and return line fitting for obstructions or Proceed to Test Step 12.
damage. Also, check that the line is connected in the proper
locations. Result: An obstruction or damage was not found.

Note : Possible obstructions are ice, DEF deposits, or debris. Repair : Reinstall the return line.

Proceed to Test Step 9.

9. Check for Manifold Leaks Leaks Result: A leak or crack was found in the suction pipe.

A. Turn the keyswitch to OFF. Repair : Replace the DEF manifold.

B. Remove the DEF manifold from the DEF tank. Proceed to Test Step 12.

C. Inspect the suction pipe on the manifold for any leaks or cracks. Result: An obstruction or damage was not found.

Repair : Reinstall the return line.

Proceed to Test Step 10.

10. Replace the DEF Pump Filters DEF Pump Result : The DEF tank was flushed, the DEF tank filters
and DEF were replaced and the DEF pump filters were replaced.
A. Turn the keyswitch to OFF. Tank Filters
Proceed to Test Step 11.
B. Clean the area around the pump filters.

C. Replace the DEF pump suction line filter fitting. Tighten the new
filter fitting to a torque of 4.5 N·m (40 lb in).

D. Replace the DEF pump filter. Refer to Operation and Mainte-

nance Manual, “Diesel Exhaust Fluid Filter - Clean/Replace” for the
correct procedure.

E. Remove DEF tank header from the DEF tank.

F. Flush the DEF tank and replace the DEF filters. Refer to Sys-
tems Operation Testing and Adjusting, Diesel Exhaust Fluid Tank -
Flush for the correct procedure.

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Illustration 17 g06339017

(5) DEF Pressure

Table 28
Troubleshooting Test Steps Values Results

11. Check the DEF Pump DEF pump Result : The DEF pump maintained at least 800 kPa
(116 psi) during the test.
A. Turn the keyswitch to the ON position. Do not start the engine.
Proceed to Test Step 12.
B. Connect to the “Aftertreatment Diesel Exhaust Fluid #1” using
the electronic service tool. Result : The DEF pump did not maintain at least 800 kPa
(116 psi) during the test.
C. Navigate to “Diagnostics Tests” .
Repair : Replace the DEF pump. Refer to Disassembly and
D. Perform the “DEF Dosing System Verification Test” to pressurize Assembly, “Diesel Exhaust Fluid Pump - Remove and In-
the system. stall” for the correct procedure.

Note: This test may take up to 30 minutes to complete. Proceed to Test Step 12.

E. Monitor the DEF Pressure (5) on the electronic service tool dur-
ing the test to see if the pressure stabilizes.

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 M0095947-10 69
Symptom Troubleshooting

Illustration 18 g06337119
(6) DEF tank header
(7) DEF header filter

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Table 29
Troubleshooting Test Steps Values Results

12. Perform an “ Aftertreatment System Functional Test”” “Aftertreatment Sys- Result: The test is successful.
tem Functional Test”
A. Start the engine. Return the unit to service.

B. Connect to the “Engine #1 Aftertreatment Controller” using Result: The test is not successful.
the electronic service tool.
Proceed to Test Step 13.
C. Navigate to “Diagnostics Tests” .

D. Perform the “Aftertreatment System Functional Test” .

13. Perform a “ DEF Dosing System Accuracy Test”” “DEF Dosing System Result: The quantity collected is below specification.
Accuracy Test” A failed DEF injector has been detected.
A. Connect to the electronic service tool.
Repair : Replace the DEF injector. Refer to Disassem-
B. Navigate to “Diagnostics Tests” . bly and Assembly, DEF Injector and Mounting - Re-
move and Install.
C. Perform a “DEF Dosing System Accuracy Test” . Refer to
Systems Operation, Testing, and Adjusting, “Aftertreatment Proceed to Test Step 14.
SCR System Dosing Test” for the correct procedure.
Result: The quantity collected is above specification.
A failed DEF injector has been detected.

Repair : Replace the DEF injector. Refer to Disassem-

bly and Assembly, DEF Injector and Mounting - Re-
move and Install.

Proceed to Test Step 14.

14. Perform an “ Aftertreatment System Functional Test”” . “Aftertreatment Sys- Result: The test is successful.
tem Functional Test”
A. Start the engine. Return the unit to service.

B. Connect to the electronic service tool. Result: The test is not successful. There are more di-
agnostic codes.
C. Navigate to “Diagnostics Tests” .
Repair : Troubleshoot the additional codes. Refer to
D. Perform the “Aftertreatment System Functional Test” . the Troubleshooting manual for the correct procedure.

Result: The test is not successful. There are no addi-

tional codes.

Contact the Dealer Solutions Network (DSN).

i08165250

DEF Tank Level Is Low

Diesel Exhaust Fluid (DEF) Tank Level

Inducement
Inducements are engine derates or other actions
intended to prompt the operator to seek repair or
maintenance of the emissions control system.

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 M0095947-10 71
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Table 30
Diagnostic Trouble Codes for DEF Tank Level Is Low

J1939 Code Code Description Comments

This code is a Level 3 inducement that becomes active when the DEF
Aftertreatment #1 DEF Tank Volume #1 :
1761-1 tank is empty. The engine is derated 100%, limited to low idle or 1000
Low - most severe (3)
RPM, and may experience 5 minute rolling shutdowns.

Aftertreatment #1 DEF Tank Volume #1 : This code is a Level 1 inducement that becomes active when the DEF
1761-17
Low - least severe (1) level is critically low.

Aftertreatment #1 DEF Tank Volume #1 : This code is a Level 2 inducement that becomes active when the DEF
1761-18
Low - moderate severity (2) level is critically low. Power loss may occur.

Follow the troubleshooting procedure to identify the root cause of the problem.

Note: If active 1761 diagnostic codes are present,

this may be due to an issue with the DEF pump which
is causing a loss of prime. Operate the machine for
several minutes and check to see if the DEF levels
recover.
Refer to Systems Operation, Testing and Adjusting,
“DEF Dosing Control System” for details on
inducement configuration options and inducement
actions for specific tank levels.

Note: Always turn the keyswitch to the OFF position

before adding DEF to the tank.
Complete the procedure in the order in which the
steps are listed.

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Table 31
Troubleshooting Test Steps Values Results

1. Check the DEF Level Gauge position Result: The gauge did not move when DEF was added to
the tank.
A. Clean dirt and debris from around the cap before removing the
cap. Proceed to Test Step 2.

B. Visually check the DEF level in the tank. If the DEF level is Result: The gauge moved when DEF was added to the
greater than 75%, proceed to Test Step 2. If the DEF level is less tank. Turn the keyswitch to the OFF position for 2 minutes
than 75%, continue with this procedure. to allow the DEF pump to purge, reset the code, and reset
the Electronic Control Module (ECM).
C. Turn the keyswitch to the ON position. Do not start the engine.
Return the unit to service.
D. Wait for at least 1 minute. Check the current position of the
DEF gauge.

E. Turn the keyswitch to the OFF position.

F. Clean dirt and debris from around the cap before removing the
cap.

G. Fill the DEF tank to at least 25% capacity.

Note: Only use DEF that meets ISO 22241 quality standards.

H. Turn the keyswitch to the ON position.

I. Check for a change in the gauge position.

2. Check the Electrical Connection for the DEF Tank Header Electrical Result: The electrical connectors are free of corrosion and
connections are not loose.
A. Inspect the electrical connector to the DEF tank header. Refer
to Troubleshooting, “Electrical Connectors - Inspect” for further Proceed to Test Step 3.
information.
Result: The electrical connections are not free of corrosion
Look for corrosion or loose wires. and/or are loose.

Repair: Make the necessary repairs to the connectors.

Turn the keyswitch to the OFF position for 2 minutes to al-
low the DEF pump to purge, reset the code, and reset the
ECM.

Repeat the procedure from Test Step 1.

3. Inspect the DEF Tank Header Correct opera- Result: The float was not operating correctly.
tion of the float
A. Turn the keyswitch to the OFF position. Repair: If possible, repair the float and then install the filter
sock. If the float cannot be repaired, replace the DEF tank
B. Remove the DEF tank header (2) from the DEF tank. Refer to header. Refer to Disassembly and Assembly, “Manifold
Disassembly and Assembly, “Manifold (DEF Heater) - Remove (DEF Heater) - Remove and Install”.
and Install”.
Return the unit to service.
C. If necessary, remove the filter sock from the DEF tank header.
Result: The float was operating correctly.
D. Inspect the DEF tank header for a stuck float.
Repair: Install a replacement DEF tank header. Refer to
Disassembly and Assembly, “Manifold (DEF Heater) - Re-
move and Install”.

If the fault is still present, contact the Dealer Solutions Net-

work (DSN).

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 M0095947-10 73
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i07512064

DEF Tank Temperature Is High

Table 32
Diagnostic Trouble Code for DEF Tank Temperature Is High

J1939 Code Code Description Comments

Aftertreatment #1 DEF Tank Temperature : High - The code is logged when the DEF tank temperature exceeds
3031-16 80° C (176° F).
moderate severity (2)

Table 33
Associated Diagnostic Trouble Codes
J1939 Code
110-0
110-15
110-16
Follow the troubleshooting procedure to identify the root cause of the fault.

Complete the procedure in the order in which the

steps are listed.
Table 34
Troubleshooting Test Steps Values Results

1. Check for Associated Codes Associated code Result: An associated code is present.

A. Connect to the electronic service tool. Repair: Troubleshoot the associated code. Refer to
Troubleshooting, “Diagnostic Trouble Codes” for the cor-
B. Determine if an associated code is present. rect procedure.

Result: An associated code is not present.

Proceed to Test Step 2.

2. Check the Electrical Connections Corrosion or Result: The connections are free of corrosion and are
loose wires not loose.
A. Inspect the electrical connections to the coolant diverter valve.
Inspect all electrical connections to the Diesel Exhaust Fluid Proceed to Test Step 3.
(DEF) tank header. Refer to Troubleshooting, “Electrical Connec-
tors - Inspect” for further information. Result: The connections are corroded and/or are loose.

B. Inspect for corrosion or loose wires. Repair: Make the necessary repairs.

Proceed to Test Step 4.

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Illustration 19 g06344718
Typical view of the DEF pump
(1) Coolant supply connection
(2) Coolant return connection

Illustration 20 g06347747
(3) Coolant diverter valve
(4) Flow direction indicator

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Symptom Troubleshooting

Table 35
Troubleshooting Test Steps Values Results

3. Check the Coolant Supply and Return Lines for Proper Correct Result: The lines are installed correctly.
Installation Installation
Proceed to Test Step 4.
A. Check the coolant supply line and the coolant return line from
the engine to the DEF pump. Make sure that the coolant is flowing Result: The lines are not installed correctly.
in the correct direction. Refer to Illustration 20 .
Repair: Correctly install the lines.

Proceed to Test Step 5.

4. Check the Coolant Diverter Valve Solenoid for Proper Temperature Result: The tank temperature did not increase.
Operation rise
Repair: Connect the coolant diverter valve to the wiring
A. Turn the keyswitch to the OFF position. harness.

B. Disconnect the coolant diverter valve wiring harness connector Proceed to Test Step 5.
from the coolant diverter valve.

C. Turn the keyswitch to the ON position. Result: The tank temperature did increase.

D. Connect to the electronic service tool. Repair: A failed coolant diverter valve has been detected.
Replace the coolant diverter valve. Refer to Disassembly
E. Start the engine. Allow the engine to warm up to operating and Assembly, “Solenoid Valve (DEF Heater Coolant) -
temperature. Remove and Install” for the correct procedure.

F. Use the electronic service tool to monitor the “DEF Tank Tem- Proceed to Test Step 5.
perature” .

G. Turn the keyswitch to the OFF position.

5. Replace the DEF DEF Result: The tank fluid was replaced.

A. Drain the DEF from the tank. Return the unit to service.

B. Fill the tank with DEF that meets ISO 22241 standards. Result: The fault is still present.

Contact the Dealer Solutions Network (DSN).

i08125419

DEF Temperature Is Low

Table 36
Diagnostic Trouble Codes for DEF Tank Temperature Is Low

J1939 Code Code Description Comments

The Electronic Control Module (ECM) detects that the Diesel Exhaust
Aftertreatment #1 DEF Tank Temperature :
3031-7 Fluid (DEF) tank temperature is not responding properly. The code is
Not Responding Properly
logged.

Aftertreatment #1 DEF Tank Temperature :

3031-18 The ECM detects that the DEF tank temperature is lower than expected.
Low - moderate severity (2)

(continued)

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(Table 36, contd)

Diagnostic Trouble Codes for DEF Tank Temperature Is Low

J1939 Code Code Description Comments

Aftertreatment #1 DEF Dosing Unit Heater The ECM detects that the DEF pump temperature sensor is not respond-
5798-7
Temperature : Not Responding Properly ing properly. The code is logged.

Follow the troubleshooting procedure to identify the root cause of the problem.

The 3031-7 code will be logged when the engine is

running, the Diesel Exhaust Fluid (DEF) tank
temperature is colder than −8° C (17.6° F) and the
DEF tank temperature started to rise, but has fallen
back below−8° C (17.6° F).
The 5798-7 code will be logged when the engine is
running, the DEF tank temperature is warmer than
−8° C (17.6° F), the DEF tank temperature has
increased, but the DEF pump temperature has not
changed.
Table 37
Associated Diagnostic Trouble Codes

J1939 Code
3363-5
3363-6
4354-5
4354-6
4355-5
4355-6
4356-5
4356-6

Complete the procedure in the order in which the

steps are listed.

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Table 38
Troubleshooting Test Steps Values Results
Diagnostic trou-
1. Check for Associated Diagnostic Trouble Codes ble codes Result: An associated diagnostic trouble code is not
present.
A. Connect the electronic service tool to the engine ECM.
Proceed to Test Step 2.
B. Determine if an associated diagnostic code is present.
Result: An associated diagnostic trouble code is present.

Repair: Troubleshoot the associated code.

2. Check the Coolant Level of the Engine Coolant level Result: The coolant level is full.

A. Determine if the engine coolant level is full. Proceed to Test Step 3.

Result:The coolant level is not full.

Repair: Add coolant to the system.

Determine the cause of low coolant. Refer to Trouble-

shooting, “Coolant Level Is Low” for additional
information.

Proceed to Test Step 3.

3. Check for Coolant Leaks Leaks Result: No leaks were detected.

A. Check the entire engine cooling system for signs of coolant Proceed to Test Step 4.
leaks.
Result: There were leaks or damaged lines detected.
B. Inspect the coolant supply and return lines to the DEF tank for
leaks or damage that may cause restrictions. Repair: Repair the leaks or damaged lines and refill the
coolant system.

Proceed to Test Step 4.

4. Check the Electrical Connection at the DEF Tank Header Electrical Result: The electrical connections are free of corrosion
connections and are not loose.
A. Inspect the electrical connector to the DEF tank header . Refer
to Troubleshooting, “Electrical Connectors - Inspect” for further Proceed to Test Step 5.
information.
Result: The electrical connections are corroded and/or
Check for corrosion or loose wires. are loose.

Repair: Make the necessary repairs to the connector.

Proceed to Test Step 5.

(continued)

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(Table 38, contd)

Troubleshooting Test Steps Values Results

5. Check the Engine Coolant Temperature Coolant Result: The coolant temperature is greater than 50° C
temperature (122° F).
A. Start the engine. Allow the engine to warm to normal operating
temperature. Proceed to Test Step 6.

B. Connect to the electronic service tool. Result: The coolant temperature is not greater than
50° C (122° F).
C. Select the “Status Parameters” tab.
Investigate the cause of low coolant temperature.
D. Check the coolant temperature.

The temperature should be greater than 50° C (122° F).

6. Check the DEF Coolant Diverter Valve Solenoid Operation Temperature Result: The DEF tank temperature increased.
rise
A. Turn the keyswitch to the ON position. Return the unit to service.

B. Start the engine. Result: The DEF tank temperature did not increase.

C. Connect to the electronic service tool. Repair: A failed coolant diverter valve has been detected.
Replace the coolant diverter valve.
D. Connect to the engine ECM.
Proceed to Test Step 7.
E. Set the status of the coolant diverter valve to OPEN using the
“DEF Coolant Diverter Valve Solenoid Override” for 20 minutes.

F. Monitor the “DEF Tank Temperature” and make sure that there
is an increase of at least 3° C (5.4° F).

Note: The DEF tank temperature must be within 5° C (9° F) of

ambient air temperature prior to performing this override.

7. Check the DEF Temperature Sensor Operation Temperature Result: The DEF tank temperature increased.
rise
A. Turn the keyswitch to the ON position. Return the unit to service.

B. Start the engine. Result: The DEF tank temperature did not increase.

C. Connect to the electronic service tool. Repair: A failed DEF tank temperature sensor has been
detected. Replace the DEF tank header assembly.
D. Connect to the engine ECM.
Repeat the “DEF Coolant Diverter Valve Solenoid Over-
E. Set the status of the coolant diverter valve to OPEN using the ride” for 20 minutes.
“DEF Coolant Diverter Valve Solenoid Override” for 20 minutes.
If there is a temperature rise in the DEF fluid, return the
F. Monitor the “DEF Tank Temperature” and make sure that there unit to service.
is an increase of at least 3° C (5.4° F).
If the fault is still present, contact the Dealer Solutions
The DEF tank temperature must be within 5° C (9° F) of ambi- Network (DSN).
ent air temperature prior to performing this override.

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 M0095947-10 79
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i07898983

Diesel Oxidation Catalyst Has

Incorrect Inlet Temperature

Table 39
Diagnostic Trouble Code for DOC Has Incorrect Inlet Temperature

J1939 Code Code Description Comments

Aftertreatment #1 Diesel Oxidation Catalyst Intake ECM detects that the DOC inlet temperature is below the acceptable
Gas Temperature : Low - least severe (1) range during HC dosing.
4765-17 The code is logged.

Follow the troubleshooting procedure to identify the root cause of the fault.

Table 40
Associated Codes
J1939 Codes
51–3
51–4
3464–5
3464–6
3464–7

Complete the procedure in the order in which the

steps are listed.

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Table 41
Troubleshooting Test Steps Values Results

1. Check for Diagnostic Trouble Codes Diagnostic trou- Result: A 4765-17 code is active or recently logged.
ble codes
A. Turn the keyswitch to the ON position. Do not start the engine. Proceed to Test Step 2.

B. Connect to the electronic service tool. Result: An associated code is active or recently logged.

C. Check for associated diagnostic trouble codes. Troubleshoot the logged or active code. Refer to Trouble-
shooting, “Diagnostic Trouble Codes”.

Result: No associated diagnostic codes are active or re-

cently logged.

Proceed to Test Step 3.

2. Check the Exhaust System Exhaust system Result: The exhaust system has a gas leak.

A. Check the exhaust system for gas leaks between the turbo- Repair: Make the necessary repairs.
charger and the Clean Emissions Module (CEM).
Proceed to Test Step 3.
B. Check for missing or damaged exhaust system insulation.
Result: The exhaust system insulation is damaged or
C. Ensure that the length of the exhaust piping between the turbo- missing.
charger and the CEM is within specifications.
Repair: Make the necessary repairs.

Proceed to Test Step 3.

Result: The exhaust system is not within the

specification.

Repair: Contact the Dealer Solutions Network (DSN).

Proceed to Test Step 3.

3. Check the Exhaust System Temperature Test Result: The “Manual Hydrocarbon Dosing Capability
Test” completed successfully.
A. Connect to the electronic service tool.
Return the unit to service.
B. Run the engine.
Result: The “Manual Hydrocarbon Dosing Capability
C. Perform the “Manual Hydrocarbon Dosing Capability Test” . Test” failed. Associated diagnostic trouble codes are
active.

Troubleshoot the logged or active code. Refer to Trouble-

shooting, “Diagnostic Trouble Codes”.

Result: The “Manual Hydrocarbon Dosing Capability

Test” failed. An error code is generated by the electronic
service tool.

Troubleshoot the error code. Refer to Troubleshooting,

“Service Tool Error Identifiers”.

Result: The “Manual Hydrocarbon Dosing Capability

Test” failed. No associated diagnostic trouble codes are
active.

Contact the Dealer Solutions Network (DSN).

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i07526970

Diesel Oxidation Catalyst Has

Low Conversion Efficiency

Table 42
Diagnostic Trouble Code for DOC Has Low Conversion Efficiency

J1939 Code Code Description Comments

ECM detects that the DOC outlet temperature is below the acceptable
Aftertreatment 1 Diesel Oxidation Catalyst Conver-
5298-17 range during HC dosing.
sion Efficiency : Low - least severe (1)
The code is logged.

Follow the troubleshooting procedure to identify the root cause of the fault.

Complete the procedure in the order in which the

steps are listed.
Table 43
Troubleshooting Test Steps Values Results

1. Check for Diagnostic Trouble Codes Diagnostic trou- Result: A 5298-17 code is active or recently logged.
ble codes
A. Turn the keyswitch to the ON position. Do not start the engine. Proceed to Test Step 2.

B. Connect to the electronic service tool. Result: A recurrence of 5298-17 code is active or re-
cently logged. The code has previously been rectified.
C. Check for diagnostic trouble codes.
Proceed to Test Step 4.

Result: An associated code other than 5298-17 is active

or recently logged.

Repair: Troubleshoot the logged or active code. Refer to

Troubleshooting, “Diagnostic Trouble Codes”.

Result: No codes are active or recently logged.

Proceed to Test Step 3.

2. Check the Exhaust System Exhaust System Result: Oil is present in the exhaust system.

A. Check the exhaust system for evidence of oil between the tur- Repair: Refer to Troubleshooting, “Exhaust System Con-
bocharger and the Clean Emissions Module (CEM). tains Oil”.

Result: There is no oil in the exhaust system.

Repair: Use the electronic service tool to perform the

“Manual Hydrocarbon Dosing Capability Test” . Proceed
to Test Step 3.

(continued)

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(Table 43, contd)

Troubleshooting Test Steps Values Results

3. Check for High Sulfur Fuel Test Result: High sulfur fuel is in use.

A. Ensure that the correct specification of fuel is being used. Refer Drain the fuel tank, flush the fuel lines, and replace the
to the Operation and Maintenance Manual for the correct fuel filters.
specification.
Refill the fuel system with fuel of the correct specification.
Note: If fuel with a high sulfur content is used, this fault will reoccur
and a replacement CEM may be required. Proceed to Test Step 4.

Result: High Sulfur fuel is not in use.

Proceed to Test Step 4.

Result: The “Aftertreatment Recovery Procedure” com-

4. Recover the Aftertreatment System Test pleted successfully.

A. Connect to the electronic service tool. Return the unit to service.

B. Run the engine. Result: The “Aftertreatment Recovery Procedure” failed.

An error code is generated by the electronic service tool.
C. Perform the “Aftertreatment Recovery Procedure” .
Repair: Troubleshoot the error code. Refer to Trouble-
shooting, “Service Tool Error Identifiers”.

Result: The “Aftertreatment Recovery Procedure” failed.

No error codes are generated.

A replacement CEM may be required. Contact the Dealer

Solutions Network (DSN).

i07988457

Diesel Particulate Filter

Collects Excessive Soot

The Electronic Control Module (ECM) uses the

differential pressure sensors to monitor the soot load
in the Diesel Particulate Filter (DPF). If the soot load
becomes excessive, the ECM activates the
applicable code.
Table 44
Diagnostic Trouble Codes for Excessive Soot Load

J1939 Code Code Description Comments

Aftertreatment #1 DPF Differential Pressure The ECM detects a high accumulation of ash within the DPF.
3251–16
High: Moderate Severity (2)

Automatic regeneration is disabled.

Diesel Particulate Filter Active Regeneration
3714–31
Inhibited Due to Temporary System Lockout
The electronic service tool must be used to recover the aftertreatment system.

Diesel Particulate Filter Active Regeneration The estimated soot load is too high for safe recovery of the aftertreatment.
3715–31
Inhibited Due to Permanent System Lockout

(continued)

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(Table 44, contd)

Diagnostic Trouble Codes for Excessive Soot Load

J1939 Code Code Description Comments

The estimated soot load is high.
DPF #1 Soot Loading Percent : High - moder-
3719-16
ate severity (2)
Engine power is gradually derated as the soot load increases.

The estimated soot load is high.

DPF #1 Soot Loading Percent : High - most se-
3719-0 Engine operation is limited to 60 second intervals when the electronic service
vere (3)
tool is not communicating with the ECM.

An excessive accumulation of soot in the DPF can be

caused by the following faults:
• Oil in the exhaust system

• A mechanical fault in a cylinder

• Faulty injectors

• Low exhaust gas pressure

• A faulty engine intake throttle
• A fault in the NOx Reduction System (NRS)

• Fuel with a high sulfur content

Engine operation must be kept to a minimum to
minimize the amount of soot that is created. Follow
the troubleshooting procedure to minimize the
amount of engine operation.
Complete the procedure in the order in which the
steps are listed.

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Table 45
Troubleshooting Test Steps Values Results

1. Check for Active Diagnostic Trouble Codes Diagnostic trou- Result: A 3719-xx, 3714–31, or 3251–16 code is active.
ble codes
A. Turn the keyswitch to the ON position. Proceed to Test Step 2.

B. Connect the electronic service tool. Result: A 3715–31 code is active.

C. Check for active diagnostic trouble codes. Contact the Dealer Solutions Network (DSN).

Result: A code other than 3719-xx, 3714–31, 3715–31,

or 3251–16 is active.

Diagnose and rectify the fault before continuing with this

procedure. Refer to Troubleshooting, “Diagnostic Trouble
Codes”.

2. Check for Oil in the Exhaust System Exhaust system Result: Oil deposits are present in the exhaust system.

A. Remove the flexible exhaust pipe. Refer to Disassembly and Refer to Troubleshooting, “Exhaust System Contains
Assembly, “Flexible Exhaust Pipe - Remove and Install”. Oil”.

B. Inspect the exhaust system and Clean Emissions Module Result: No oil deposits are found in the exhaust system.
(CEM) inlet for oil deposits.
Proceed to Test Step 3.

Result: The results of the compression test are outside

3. Low Compression (Cylinder Pressure) Cylinder the specifications.
compression
A. Perform a compression test. Refer to Systems Operation, Test- Repair: Investigate the cause and rectify any faults.
ing, and Adjusting, “Compression - Test”.
Note: Possible causes of low compression are shown in
the following list:

· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Result: The results of the compression test are OK.

Proceed to Test Step 4.

(continued)

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(Table 45, contd)

Troubleshooting Test Steps Values Results

4. Electronic Unit Injectors Electronic Unit Result: A faulty injector is indicated.

Injectors
A. Use the electronic service tool to perform the automatic “Cylin- Repair: Remove any faulty electronic unit injectors. Re-
der Cutout Test” . Refer to Troubleshooting, Service Tool Features fer to Disassembly and Assembly, “Electronic Unit Injec-
for more information on understanding the results of the “Cylinder tor - Remove”.
Cutout Test” .
Install new electronic unit injectors. Refer to Disassembly
Note: If the compression test that was performed in Test Step 4 and Assembly, “Electronic Unit Injector - Install”.
was satisfactory, the “Cylinder Cutout Test” will identify any faulty
injectors. Repeat the automatic “Cylinder Cutout Test” . If the fault
is still apparent, remove the replacement electronic unit
injector and install the original electronic unit injector. Re-
fer to Disassembly and Assembly, “Electronic Unit Injec-
tor - Remove” and Disassembly and Assembly,
“Electronic Unit Injector - Install”.

Result: All injectors are OK.

Proceed to Test Step 5.

5. Check the Engine Intake Throttle Valve and the NRS Diagnostic Result: The “Air System Motor Valve Verification Test”
system codes failed. A diagnostic code is present that is associated
with the engine intake throttle valve or the NRS system.
A. Use the Electronic service tool to perform the “Air System Mo-
tor Valve Verification Test” . Refer to Troubleshooting, “Diagnostic Trouble Codes” for
information on troubleshooting the code.

Result: The “Air System Motor Valve Verification Test”

passed. There are no diagnostic codes present for the
engine intake throttle valve or the NRS system.

Proceed to Test Step 6.

6. Check for High Sulfur Fuel Fuel Result: High sulfur fuel is in use.

A. Ensure that the correct specification of fuel is being used. Refer Repair: Drain the fuel tank, flush the fuel lines, and re-
to the Operation and Maintenance Manual for the correct place the fuel filters.
specification.
Refill the fuel system with fuel of the correct specification.
Note: If fuel with a high sulfur content is used, this fault will reoc-
cur and a replacement CEM may be required. Proceed to Test Step 7.

Result: The fuel is the correct specification.

Contact the Dealer Solutions Network (DSN).

7. Recover the Aftertreatment System DPF Result: The soot content of the DPF returns to normal.

A. Start the engine and use the electronic service tool to perform Use the electronic service tool to clear all related diag-
the “Aftertreatment Recovery Procedure” . nostic codes. Operate the engine to ensure that the fault
has been eliminated.
Return the unit to service.

Result: The soot content of the DPF remains high.

Contact the Dealer Solutions Network (DSN).

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i07988492

Diesel Particulate Filter Has

Low Inlet Pressure

Use this procedure if the following event code is

active.
Table 46
J1939 Code and Description Description Comments

3251–1 Aftertreatment #1 DPF Differ- The code detects an implausibly low DPF differential pressure which indicates
ential Pressure : Low - most reverse installation of the DPF differential pressure sensor.
severe (3)
The shutdown lamp will illuminate.

The warning lamp will flash fast.

The Emissions Systems Malfunction Lamp will flash fast.

3251-18 Aftertreatment #1 DPF Differ- The code indicates the detection of the removal of the DPF substrate.
ential Pressure : Low - moder-
ate severity (2) The warning lamp will flash slowly.

Table 47
Troubleshooting Test Steps Values Results

1. Inspect the Exhaust System for Leaks Exhaust Leaks Result: The exhaust system has leaks.

A. Inspect the exhaust system for leaks between the exhaust Repair: Repair the exhaust. Return the engine to
manifold and the Clean Emissions Module (CEM). service.

B. Check the exhaust system for loose connections or open Result: The exhaust system does not have leaks.
ports.
Proceed to Test Step 2.

Damaged DPF
2. Inspect the Diesel Particulate Filter Brick Result: The DPF has a damaged or missing DPF brick.

A. Inspect the inlet of the DPF. Inspect the DPF for a missing or Repair: Replace the damaged DPF or missing DPF
damaged DPF brick. brick. Return the engine to service.

If the procedure did not correct the issue, contact the

Dealer Solutions Network (DSN).

i07528505

Diesel Particulate Filter

Temperature Is Low

The Electronic Control Module (ECM) monitors the

temperature at the intake of the Diesel Particulate
Filter (DPF). The ECM activates the following
diagnostic code when the conditions are met.

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Table 48
Diagnostic Trouble Codes for Diesel Particulate Filter Temperature Is Low

J1939 Codes Code Description Comments

The temperature sensor is not correctly installed.
Aftertreatment #1 DPF Intake Gas Temperature : Low - moder-
3242-18
ate severity (2) Engine power is derated 30%. The code is logged. The code
remains active until electrical power to the ECM is cycled.

Complete the procedure in the order in which the

steps are listed.
Table 49
Troubleshooting Test Steps Values Results

1. Check for Active Diagnostic Trouble Codes Diagnostic trou- Result: A 3242-18 code is active.
ble codes
A. Turn the keyswitch to the ON position. Proceed to Test Step 2.

B. Connect the electronic service tool. Result: A code other than 3242-18 is active.

C. Check for active diagnostic trouble codes. Repair: Diagnose and rectify the fault before continuing
with this procedure. Refer to Troubleshooting, “Diagnos-
tic Trouble Codes”.

2. Check the Sensor Installation Sensor Result: The temperature sensor is not correctly installed
installation or is loose.
A. Check that the temperature sensor is correctly installed and is
not loose. Repair: Install the temperature sensor and tighten to the
recommended torque. Refer to Disassembly and Assem-
bly, “Temperature Sensor (DPF) - Remove and Install”.

Proceed to Test Step 3.

Result: The temperature sensor is correctly installed and

is not loose.

Proceed to Test Step 3.

Result: The fault has been eliminated.

3. Check if the Fault has Been Eliminated Diagnostic
Return the unit to service.
A. Start the engine.
Result: The fault is still present.
B. Use the electronic service tool to check that the fault has been
eliminated. Contact the Dealer Solutions Network (DSN).

i08293639

Ether Actuation Occurrence Is

Excessive

Use this procedure to troubleshoot the following

code:

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Table 50
Diagnostic Trouble Codes for Engine Overcrank Occurrence

J1939 Code Code Description Comments

Engine Start Enable Device 1 : High - Control system has detected high number of ether solenoid activation events since
626-0
most severe (3) last successful start.

Engine Start Enable Device 1 : High - Control system has detected high number of ether solenoid activation events since
12853-0
most severe (3) last successful start.

Probable Causes
Multiple failed starts with an ether wiring fault.
Multiple failed starts in cold climate conditions with
any of the following:
• Diagnostic codes

• Visible faults
• Air intake and exhaust system

• Speed/timing sensor
• Low-pressure fuel system

• Transfer Pump Inlet Regulator (TPIR)

• EFLP flow rate

• Return fuel lines

• High-pressure fuel system

• Low compression (cylinder pressure)

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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Table 51
Troubleshooting Test Steps Values Results

1. Download Information Using the Electronic Service Tool Diagnostic Result: The information was successfully saved.
codes
A. Use the electronic service tool to download the “Product Sta- Proceed to Test Step 2.
tus Report” (PSR) with histograms before performing any trou-
bleshooting or clearing any diagnostic codes. Result: The electronic service tool information was not suc-
cessfully saved.
Note: The downloaded information will be required by the Deal-
er Solutions Network (DSN). Contact the Dealer Solutions Network (DSN)

2. Create an Electronic Service Tool Snapshot Starting aids Result: The electronic service tool snapshot was success-
fully saved.
A. Select “Snapshot Viewer” on the electronic service tool, using
menus: Information -> Snapshot -> Viewer Proceed to Test Step 3.

B. Select the first diagnostic code and click “View Graph” . Result: The electronic service tool snapshot was not suc-
Select the following parameter and then click OK: cessfully saved.

1) Engine Speed Contact the DSN for guidance.

C. Select Save to “File to save” a Snapshot File (*.xml). This file

will contain all the data in the snapshot and not only the data
shown on the graph.

D. Repeat procedure for all diagnostic codes that contains

stored snapshot engine data.

Note: The downloaded information will be required by the DSN

if troubleshooting assistance is required.

(continued)

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 90 M0095947-10
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(Table 51, contd)

Troubleshooting Test Steps Values Results

3. Check for Active or Logged Diagnostic Codes Excessive Result: A 626-6 code is present.
load
Note: The ether canister must be removed prior to perform- Proceed to Troubleshooting, Ether Starting Aid - test to re-
ing this procedure solve the code. Once code is cleared proceed to Test Step 4.

A. Verify that the keyswitch is in the OFF position. No diagnostic codes are present.

B. Remove the ether canister. Proceed to Test Step 4.

C. Connect the electronic service tool to the diagnostic

connector.

D. Turn the keyswitch to the ON position.

E. Check for the active or logged diagnostic codes that relate to

the ether injection system.

4. Crank Engine Until Diagnostic Code Clears Battery Result: Diagnostic code clears and engine starts.

A. Crank the engine until the diagnostic code clears Note: Allow engine to run for 5 minutes to allow the system
to purge and prevent reactivation occurring.
Note: If cranking time exceeds 30s, stop cranking and allow
starter motor to cool before cranking again. Ether injection will then be re-enabled after a keycycle.

Note: Do not power cycle ECM between cranks as this will reset Result: Diagnostic code clears but engine does not start.
any clearing timers.
Warning: Ensure that ether canister has been removed.
Note: If mechanical cranking interlock is active on keyswitch Active diagnostic code must have been cleared through
mechanism, a rapid keycycle from IGNITION -> OFF -> IGNI- engine cranking prior to next step as mitigation against
TION will not result in the ECM being power cycled. ether accumulated in the exhaust system combusting.

B. Once diagnostic code clears, fuel injection will be re-enabled. Uninstall Ether in the service tool configuration screen:
Engine must be started and run for 5 minutes to prevent reacti-
vation after a complete engine power down. A. Connect to the electronic service tool.

B. Select the “Service” tab.

C. Select the “Configuration” tab to view the configuration

parameters.

D. Expand “Engine Configuration Parameters” heading.

E. Set Ether Solenoid Configuration = Not Installed. See illus-

tration 21

Proceed to Troubleshooting, Engine Cranks but Does Not

Start.

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 M0095947-10 91
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Illustration 21 g06442579
Ether Solenoid Configuration window

Table 52

5. Verify the Repair Battery circuit Result: The plunger moved up when the override was
active.
A. Once engine has successfully started and run, reinstall Ether
in the service tool configuration screen: Install the ether bottle and return the unit to service.
1: Connect to the electronic service tool.
Result: The plunger did not move when the override was
2. Select the “Service” tab. active.

3. Select the “Configuration” tab to view the configuration Proceed to Troubleshooting, Ether Starting Aid -Test.
parameters.

4. Expand “Engine Configuration Parameters” heading.

5. Set Ether Solenoid Configuration = Not Installed. See

illustration

6. Power cycle the engine ECM

B. Activate the Ether Injection Override

C. Verify that the plunger moved up when the override was

active.

i08166070 • Air intake and exhaust system

Engine Cranks but Does Not • Speed/timing sensor

Start • Low-pressure fuel system

• Return fuel lines

• High-pressure fuel system

Probable Causes
• Starting aids
• Diagnostic codes
• Low compression (cylinder pressure)
• Visible faults

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Recommended Actions
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

Note: The procedures have been listed in order of

probability. Complete the procedures in order.

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Table 53
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Diagnostic codes Result: A diagnostic code is present.

A. Download the Histograms before performing any trouble- Repair: Troubleshoot the code and then reset the histo-
shooting or clearing any diagnostic codes. gram. Refer to Troubleshooting, Diagnostic Trouble Codes
or Troubleshooting, Event Codes.
Note: The downloaded information will be required by the Deal-
er Solutions Network (DSN) if troubleshooting assistance is Result: A diagnostic code is not present.
needed. Proceed to Test Step 2.

B. Use the electronic service tool to check for active or logged

codes.

2. Visible Faults Visible faults Result: The fuel supply valve (if equipped) is not in the
OPEN position.
A. Check that the fuel supply valve (if equipped) is in the OPEN
position. Repair: Move the fuel supply valve to the OPEN position.

B. Check for the correct level of fuel, oil, and coolant. Result: The level of fuel, oil, or coolant is not correct.

C. Check for water in the primary fuel filter/water separator. Repair: Replenish any fluids with an incorrect level.

D. If the ambient temperature is below 0 °C (32 °F), check the Result: Water is present in the primary fuel filter/water
specification of engine oil and oil for the machine. separator.

E. Visually inspect the engine for the following faults: Repair: Drain any water from the primary fuel filter/water
separator.
· Missing components
· Damaged components Result: The correct specification of engine oil and oil for
· Damaged electrical cables or loose electrical cables the machine is not in use.
· Oil leaks
· Fuel leaks Repair: Replenish the system with oil of the correct specifi-
· All fuel filters are correctly installed. cation for the ambient conditions.

F. Check that the battery voltage is correct. Result: Battery voltage is low.

G. Use the electronic service tool to check the average cranking Repair: Check the batteries. Refer to Troubleshooting,
speed of the engine. “Battery Problem”.

Result: The cranking speed is less than 150 rpm.

Repair: Investigate the cause of the low cranking speed

and rectify, as necessary.

Note: If the DPF frequently collects excessive soot prior to

this fault, there may be a faulty cylinder in the engine. Pro-
ceed to Test Step 12.
Result: All checks are OK.

Proceed to Test Step 3.

(continued)

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(Table 53, contd)

Troubleshooting Test Steps Values Results

3. Check the “ Engine Starting”” Screen on the Electronic “Engine Starting” Result: The battery voltage is low.
Service Tool screen
Repair: Refer to Troubleshooting, Electrical Power Supply
A. Use the electronic service tool to check the “Engine Starting” - Test.
screen while cranking the engine.
Result: The engine cranking speed is less than 150 rpm.
B. Check that the battery voltage is greater than 9 V for a 12 V
system or 18 V for a 24 V system. Repair: Refer to Troubleshooting, Engine Does not Crank.

C. Check that the engine speed is greater than 150 rpm. Result: The “Injector Disable” parameter is not set to “Off” .

D. Check that the “Injector Disable” parameter is set to “Off” . Repair: Proceed to Test Step 11.

E. Check that the “Fuel Rail Pressure” is greater than 25 MPa Result: The “Fuel Rail Pressure” is less than 25 MPa
(3625 psi). (3625 psi).

F. Check that the “Primary Engine Speed Sensor Timing Pattern Proceed to Test Step 6.
Status” and “Secondary Engine Speed Sensor Timing Pattern
Status” indicate “Detected” . Result: The “Primary Engine Speed Sensor Timing Pattern
Status” or “Secondary Engine Speed Sensor Timing Pat-
tern Status” does not indicate “Detected” .

Proceed to Test Step 5.

Result: All parameters on the “Engine Starting” screen are

OK.

Proceed to Test Step 4.

4. Air Intake and Exhaust System Air and Exhaust Result: The air filter is restricted.
System
A. Check the air filter restriction indicator, if equipped. restrictions Repair: Replace the air filter.

B. Check the air intake and exhaust systems for the following Result: There are system restrictions.
defects:
Refer to Systems Operation, Testing and Adjusting, “Air In-
· Blockages let and Exhaust System” for additional information on the
· Restrictions air inlet and exhaust systems.
· Damage to lines or hoses
Result: The air intake and exhaust system are OK.

Proceed to Test Step 5.

5. Speed/Timing Sensors Speed/timing Result: The speed/timing sensors are not operating
sensor correctly.

A. Crank the engine and observe the engine speed on the elec- Repair: Test the speed/timing sensors. Refer to Trouble-
tronic service tool status screen. shooting, “Speed/Timing - Test”.

Note: Upon initial cranking, the status for engine speed may in- Result: The speed/timing sensors are operating correctly.
dicate that the engine speed signal is abnormal. This message
will be replaced with an engine speed once the ECM is able to Proceed to Test Step 6.
calculate a speed from the signal.

(continued)

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(Table 53, contd)

Troubleshooting Test Steps Values Results

6. Starting Aids Starting aids Result: One or more of the glow plugs are faulty.

A. Check the operation of the glow plugs. Refer to Trouble- Repair: Replace any faulty glow plugs. Refer to Disassem-
shooting, “Glow Plug Starting Aid - Test”. bly and Assembly, “Glow Plug - Remove and Install”.

B. If equipped, check the operation of the ether starting aid. Re- Check that the engine starts normally.
fer to Troubleshooting, “Ether Starting Aid - Test”.
If the engine will not start, proceed to Test Step 7.

Result: The ether starting aid is faulty.

Repair: Diagnose the ether system. Refer to Troubleshoot-

ing, “Ether Starting Aid - Test”.

Check that the engine starts normally.

If the engine will not start, proceed to Test Step 7.

7. Low-Pressure Fuel System Low-pressure Result: The fuel tank level is low.
fuel system
A. Visually check the fuel tank for fuel. Repair: Fill the fuel tank.
Note: The fuel gauge may be faulty.
Result: The fuel contains solidified wax.
B. If the temperature is below 0 °C (32 °F), check for solidified
fuel (wax). Repair: Replace the fuel with fuel of the correct specifica-
tion for the ambient conditions.
C. Check the primary filter/water separator for water in the fuel.
Replace any filters and/or screens in the fuel system. Refer
D. Check for fuel supply lines that are restricted or not correctly to Operation and Maintenance Manual for further
installed. information.

E. Check that the electric fuel priming pump is operating Result: There are fuel supply lines that are restricted or not
correctly. correctly installed.

F. Check for air in the fuel system and that the fuel system is Repair: Install the fuel lines correctly. Replace any dam-
primed. aged or restricted fuel lines.

G. Check the diesel fuel for contamination. Refer to Systems Result: The electric fuel priming pump is not operating
Operation, Testing, and Adjusting, “Fuel Quality - Test”. correctly.

Investigate the fault with the EFLP. Refer to Troubleshoot-

ing, “Fuel Transfer Pump - Test”.

Result: There is air in the fuel system.

Repair: Prime the fuel system. Refer to Systems Opera-

tion, Testing, and Adjusting, “Fuel System - Prime”.

Result: The diesel fuel is contaminated.

Repair: Drain the fuel tank and the fuel system.

Replace any filters and/or screens in the fuel system. Refer

to Operation and Maintenance Manual for further
information.

(continued)

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(Table 53, contd)

Troubleshooting Test Steps Values Results
Fill and prime the fuel system with fuel of the correct specifi-
cation. Refer to Systems Operation, Testing, and Adjusting,
“Fuel System - Prime”.

Result: The low-pressure fuel system is OK.

Proceed to Test Step 8.

8. Check the Return Fuel Lines Return lines Result: The fuel return lines are blocked or kinked.

A. Make sure that the fuel return lines are not blocked or Repair: Clear or replace the blocked line.
kinked.
Result: The fuel return lines are clear.

Proceed to Test Step 9.

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

NOTICE
Contact with high-pressure fuel may cause personal
injury or death. Wait 10 minutes after the engine has
stopped to allow fuel pressure to purge before any
service or repair is performed on the engine fuel
lines.

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 M0095947-10 97
Symptom Troubleshooting

Table 54
Troubleshooting Test Steps Values Results

9. High-Pressure Fuel System High-pressure Result: The absolute fuel rail pressure is less than 25 MPa
fuel system (3625 psi).
A. Use the electronic service tool to check the absolute fuel rail
pressure while the engine is cranking at a minimum speed of Repair: Check for fuel leaks in the high-pressure fuel sys-
150 rpm. tem. Rectify any fuel leaks and then recheck the pressure
in the fuel rail.

Use the electronic service tool to perform a solenoid test on

the fuel injection pump. Refer to Troubleshooting, “Solenoid
Valve - Test”.

Check the Pressure Limiting Valve (PLV) in the fuel rail for
leakage. If the valve is leaking, replace the valve and re-
check the pressure in the fuel rail.

Check for fuel in the engine oil system. If fuel is suspected

in the oil system, take an engine oil sample for analysis.
Refer to the Operation and Maintenance Manual, “Engine
Oil Sample - Obtain”.

If the analysis confirms that there is fuel in the engine oil

system, investigate the cause.

Result: The absolute fuel rail pressure is greater than

25 MPa (3625 psi).

Use the electronic service tool to make sure that the status
of the electronic unit injectors is not “Disabled” .

If the injectors are disabled but the injectors have not been
intentionally disabled, proceed to Test Step 11.

Use the electronic service tool to perform an injector sole-

noid test. Refer to Troubleshooting, “Injector Solenoid -
Test”. If the engine will not start, proceed to Test Step 10.

10. Electronic Control Module (ECM) ECM Result: Installation of the latest flash file does not eliminate
the fault.
A. Make sure that the latest flash file for the application is in-
stalled in the ECM. Repair: Contact the Dealer Solutions Network (DSN).

Note: This consultation can greatly reduce the repair time.

If the DSN recommends the use of a test ECM, install a test

ECM. Refer to Troubleshooting, “ECM - Replace”.

Attempt to start the engine. If the engine will not start, install
the original ECM and then proceed to Test Step 11.

If the engine starts normally, reconnect the suspect ECM

and then verify that the fault returns when the suspect ECM
is installed.

If the engine will not start with the suspect ECM, replace
the ECM and then check that the engine starts normally.

(continued)

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Symptom Troubleshooting

(Table 54, contd)

Troubleshooting Test Steps Values Results

11. High-Pressure Fuel Pump HP fuel pump Result: The timing of the high-pressure fuel pump is
incorrect.
A. Check the timing of the high-pressure fuel pump. Refer to
Systems Operation, Testing, and Adjusting, “Fuel Injection Tim- Repair: Correct the timing of the high-pressure fuel pump.
ing - Check”. Refer to Disassembly and Assembly, “Fuel Injection Pump -
Remove” and Disassembly and Assembly, “Fuel Injection
Pump - Install”.

With the high-pressure fuel pump correctly timed, check

that the engine starts normally.

If the engine will not start, proceed to Test Step 12.

Result: The timing of the high-pressure fuel pump is

correct.

Repair: Replace the high-pressure fuel pump. Refer to Dis-

assembly and Assembly, “Fuel Injection Pump - Remove”
and Disassembly and Assembly, “Fuel Injection Pump -
Install”.

Check that the engine starts normally.

If the engine will not start, proceed to Test Step 12.

12. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside the
compression specifications.
A. Perform a compression test. Refer to Systems Operation,
Testing, and Adjusting, “Compression - Test”. Repair: Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown in

the following list:

· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Result: The results of the compression test are OK.

Contact the Dealer Solutions Network (DSN).

i07531723

Engine Does Not Crank

Use this procedure to troubleshoot an engine that will

not crank.
Complete the procedure in the order in which the
steps are listed.

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 M0095947-10 99
Symptom Troubleshooting

Table 55
Troubleshooting Test Steps Values Results

1. Inspection of the Batteries and Battery Cables Batteries Result The batteries and cables are OK.

A. Inspect the main power switch, battery posts, and battery ca- Proceed to Test Step 2.
bles for loose connections and for corrosion. If the battery ca-
bles are corroded, remove the battery cables and clean the Result The batteries and cables are not OK.
battery cables. Tighten any loose connections.
Repair: Make the necessary repairs.
B. Inspect the batteries.

C. Charge the batteries. Refer to Systems Operation, Testing

and Adjusting, “Battery - Test”.

2. Switches and/or Circuit Breakers (if applicable) Switches and/or Result The switches and/or circuit breakers are OK.
circuit breakers
A. Check any switches and/or circuit breakers that may prevent Proceed to Test Step 3.
engine cranking. For additional information, refer to the electri-
cal schematic for the application. Result The switches and/or circuit breakers are not OK.

Repair: Make the necessary repairs.

3. Starting Motor Solenoid and Starting Circuit Starting motor Result The starting motor solenoid and circuit are OK.
solenoid and
A. Test the operation of the starting motor circuit. Refer to Sys- circuit Proceed to Test Step 4.
tems Operation, Testing, and Adjusting, “Electrical System” for
additional information. Result The starting motor solenoid and circuit are not OK.

Repair: Make the necessary repairs.

4. Inspect the Starter Pinion and Flywheel Ring Gear Starter pinion Result The starter pinion and flywheel ring gear are OK.
and flywheel ring
A. Test the operation of the starting motor. gear Proceed to Test Step 5.

B. Check the pinion clearance. Inspect the pinion and the fly- Result The starter pinion and flywheel ring gear are not
wheel ring gear for damage. Refer to Systems Operation, Test- OK.
ing, and Adjusting, “Electrical System” for additional
information. Repair: Make the necessary repairs.

(continued)

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Symptom Troubleshooting

(Table 55, contd)

Troubleshooting Test Steps Values Results

5. Inspect Engine Accessories and the Transmission (if Engine accesso- Result The engine accessories and transmission are OK.
applicable) ries and
transmission Proceed to Test Step 6.
A. Ensure free movement of the driveline.
Result The engine accessories and transmission are not
B. Remove and inspect any engine accessories that may lock OK.
up the engine.
Repair: Make the necessary repairs.
The following list identifies engine accessories that may lock up
the engine:

· Hydraulic pump that is driven from the rear gear group

· Air compressor

· Engine oil pump

· Other components that are driven by the engine

6. Hydraulic Cylinder Lock Hydraulic cylin- Result The engine has a hydraulic cylinder lock.
der lock
A. If the engine will not start, check for fluid in the cylinders (hy- Repair: Make the necessary repairs.
draulic cylinder lock) by removing the individual unit injectors.
Check for damaged seals. Determine the type of fluid that Result The engine does not have a hydraulic cylinder lock.
locked up the cylinder.
Contact the Dealer Solutions Network (DSN).
C. If there was a coolant leak, determine the cause of the leak.
Check the exhaust (NRS) cooler for leaks. Refer to Systems
Operation, Testing and Adjusting, “Exhaust Cooler (NRS) -
Test”.

D. If there was excessive fuel in the cylinder, replace the seals

and reinstall the injector. Drain any excess fuel from the cylinder
head.

E. If a mechanical problem is suspected, disassemble the en-

gine. Refer to the Disassembly and Assembly manual. Inspect
the internal components for the following conditions:

· Seizure

· Broken components

· Bent components

i06010812 • Dirt in fuel

Engine Has Early Wear • Low oil pressure

Recommended Actions
Note: The procedures have been listed in order of
Probable Causes probability. Complete the procedures in order.
• Incorrect maintenance intervals and/or incorrect
oil
• Contaminated engine oil

• Leaks in air intake system

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 M0095947-10 101
Symptom Troubleshooting

Table 56
Troubleshooting Test Steps Values Results

1. Incorrect Maintenance Intervals and/or Incorrect Oil Maintenance Result: The engine oil was not changed at the interval
intervals that is recommended by the Operation and Maintenance
A. Use engine oil that is recommended and change the engine oil Manual.
at the interval that is recommended by the engines Operation and
Maintenance Manual. Repair: Use the recommended grade of oil.

Change the engine oil at the interval that is recom-

mended. Repair or replace any damaged parts.

Result: The engine oil was changed at the interval that is

recommended by the engines Operation and Mainte-
nance Manual.

Proceed to Test Step 2.

2. Contaminated Engine Oil Contamination Result: The oil is contaminated.

A. Obtain an oil analysis. The analysis will identify oil Repair: Determine the reason for any contamination of
contamination. the engine oil and make the necessary repairs. Drain the
crankcase and refill the crankcase with clean engine oil.
B. Check the oil filter bypass valve. Install new engine oil filters. Refer to the engines Opera-
tion and Maintenance Manual.
Note: If the oil filter bypass valve is open, the oil will not be
filtered. Result: The oil filter bypass valve is open.

Repair: Replace the oil filter element. Refer to the Opera-

tion and Maintenance Manual.

Check the oil filter bypass valve for a weak spring or for a
broken spring. If the spring is broken, replace the spring.
Verify that the oil bypass valve is operating correctly.

Result: The oil is not contaminated.

Proceed to Test Step 3.

3. Leaks in Air Intake System Air leak Result: There are air leaks.

Note: A leak in the air intake system may allow unfiltered air into Repair: Repair any leaks.
the engine.
Result: There are no air leaks.
A. Inspect the air intake system for streaks which may indicate a
leakage of unfiltered air. Inspect all of the gaskets and the connec- Proceed to Test Step 4.
tions. Refer to Systems Operation, Testing, and Adjusting, “Air In-
let and Exhaust System” for more information.

(continued)

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 102 M0095947-10
Symptom Troubleshooting

(Table 56, contd)

Troubleshooting Test Steps Values Results

4. Dirt in Fuel Fuel and fuel Result: The fuel has contamination.
filters
A. Remove the fuel filters. Inspect the fuel filters for Repair: Determine the cause of any contamination and
contamination. make the necessary repairs.

Note: Contaminants in the fuel such as hydrogen sulfide and sul- Install new fuel filters. Refer to the Operation and Mainte-
fur can lead to the formation of acids in the crankcase. nance Manual.

B. Obtain a fuel analysis. Result: The fuel is not contaminated.

Proceed to Test Step 5.

5. Low Oil Pressure Oil pressure Result: Analysis indicates that the oil is contaminated.

Note: Engine oil that is contaminated with another liquid can Repair: Replace the oil and the oil filter. Refer to the Op-
cause low engine oil pressure. High engine oil level can be an in- eration and Maintenance Manual.
dication of contamination.
Result: The inlet tube has a restriction.
A. Obtain an analysis of the engine oil.
Repair: Clear the obstruction. Verify the repair.
B. Check the inlet screen on the suction tube and remove any ma-
terial that may be restricting engine oil flow. Result: The oil pressure is low.

Note: The inlet screen of the suction tube for the engine oil pump Refer to Troubleshooting, “Oil Pressure Is Low” for the
can have a restriction. This restriction will cause cavitation and a testing procedure. Repair any identified faults.
loss of engine oil pressure.
Result: The oil pressure is normal.
Note: When some components of the engine show wear in a short
time, the cause can be a restriction in a passage for engine oil. An Contact the Dealer Solutions Network (DSN).
indicator for the engine oil pressure may indicate sufficient pres-
sure, but a component is worn due to a lack of lubrication. In such
a case, look at the passage for the engine oil supply to the compo-
nent. Refer to Systems Operation/Testing and Adjusting, “Lubrica-
tion System” for additional information.

i07578738 • Pistons and connecting rods

Engine Has Mechanical Noise • Crankshaft

(Knock) Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Probable Causes
• Active codes and logged codes
• Electrical connections

• Fuel injection
• Fuel quality

• Lubrication
• Engine accessory

• Valve train components

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 M0095947-10 103
Symptom Troubleshooting

Table 57
Troubleshooting Test Steps Values Results

1. Active Codes and Logged Codes Codes Result: There are active codes.

A. Establish communication between the electronic service tool Repair: Troubleshoot any active codes before continuing
and the Electronic Control Module (ECM). Refer to Troubleshoot- with this procedure.
ing, “Electronic Service Tools”, if necessary.
Result: There are no active codes.

Proceed to Test Step 2.

2. Electrical Connections Connectors Result: There are suspect connectors.

A. Check for the correct installation of the ECM J1/P1 and the J2/ Repair: Repair connectors that are suspect or replace con-
P2 connectors. Check for correct installation of the fuel injector nectors that are suspect.
connectors.
Perform the “Wiggle Test” on the electronic service tool.

Result: There are no suspect connectors.

Proceed to Test Step 3.

3. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside the
compression specifications.
A. Perform a compression test. Refer to Systems Operation, Test-
ing, and Adjusting, “Compression - Test”. Repair: Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown in the

following list:

· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Result: The results of the compression test are OK.

Proceed to Test Step 4.

(continued)

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Symptom Troubleshooting

(Table 57, contd)

Troubleshooting Test Steps Values Results

4. Electronic Unit Injectors Electronic Result: A faulty injector is indicated.

Unit Injectors
A. Use the electronic service tool to perform the automatic “Cylin- Repair: Remove any faulty electronic unit injectors. Refer to
der Cutout Test” . Refer to Troubleshooting, Service Tool Features Disassembly and Assembly, “Electronic Unit Injector -
for more information. Remove”.

Note: If the compression test that was performed in Test Step 3 Install new electronic unit injectors. Refer to Disassembly
was satisfactory, the “Cylinder Cutout Test” will identify any faulty and Assembly, “Electronic Unit Injector - Install”.
injectors.
Repeat the automatic “Cylinder Cutout Test” . If the fault is
still apparent, remove the replacement electronic unit injec-
tor and install the original electronic unit injector. Refer to
Disassembly and Assembly, “Electronic Unit Injector - Re-
move” and Disassembly and Assembly, “Electronic Unit In-
jector - Install”.

Result: All injectors are OK.

Proceed to Test Step 5.

5. Fuel Quality Fuel Result: The fuel quality is OK.

A. Refer to Operation and Maintenance Manual for information on Proceed to Test Step 6.
the correct characteristics of the fuel for the engine. If necessary,
obtain a fuel analysis to confirm that the correct fuel is being used Result: The fuel quality is not OK.
for the engine. Refer to Systems Operation, Testing and Adjusting,
“Fuel Quality - Test” for the correct procedure. Repair: Replace the fuel. Verify that the repair eliminated
the fault.

6. Lubrication Lubrication Result: The oil passages are not blocked and the engine
has sufficient lubrication.
A. Check for sufficient lubrication of the valve components.
Proceed to Test Step 7.
B. Check for blocked oil passages. Oil passages must be clean.
Clean any oil passages that are suspect. Refer to the Disassembly Result: The oil passages are blocked or the engine does
and Assembly for additional information. not have sufficient lubrication.

C. Inspect the engine oil filters for ferrous material. Repair: Make the necessary repairs, Verify that the repair
eliminated the fault.
D. Obtain an oil analysis.

Note: The analysis will contribute to a better understanding of oil

contamination and the origin of the contamination.

7. Engine Accessory Engine Result An engine accessory is the source of the noise.
accessory
A. If the source of the noise is an engine accessory, remove and Repair: Repair and/or replace the engine accessory, if
inspect the suspect item. necessary.

Result An engine accessory is not the source of the noise.

Proceed to Test Step 8.

(continued)

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 M0095947-10 105
Symptom Troubleshooting

(Table 57, contd)

Troubleshooting Test Steps Values Results

8. Valve Train Components Valve train Result: The valve train components are not damaged.

A. Check the valve lash. Refer to Troubleshooting, “Valve Lash Is Proceed to Test Step 9.
Excessive”.
Result: The valve train components are damaged.
B. Check for damage to valve train components. Remove the
valve cover from the suspect cylinders. Check the following items Repair: Make the necessary repairs, Verify that the repair
for damage: eliminated the fault.

· Camshaft

· Valve springs

· Camshaft followers

· Rocker shaft

· Valve bridges

· Pushrods

· Injectors

Refer to Disassembly and Assembly for additional information.

C. Check for valves that do not move freely. Remove the cylinder
head and inspect the valves.
Refer to Disassembly and Assembly for additional information.

9. Pistons and Connecting Rods Pistons and Result: One or more components are worn or damaged.
connecting
A. Inspect the pistons for damage and wear. rods Replace any worn or damaged parts.

B. Inspect the connecting rod bearings for damage and wear. Verify that the repair has eliminated the noise.

Result: All components are OK.

Proceed to Test Step 10.

10. Crankshaft Crankshaft Result: The crankshaft or the related components are dam-
aged or worn.
A. Inspect the crankshaft and the related components. Look for
worn thrust plates and wear on the crankshaft. Repair: Repair or replace any damaged parts. Verify that
the repair eliminated the fault.
B. Inspect the connecting rod bearings and the bearing surfaces
on the crankshaft. Make sure that the bearings are in the correct Result: All components are OK.
position.
Contact the Dealer Solutions Network (DSN).

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 106 M0095947-10
Symptom Troubleshooting

i08166204

Engine Misfires, Runs Rough

or Is Unstable

Note: If the fault is intermittent and the fault cannot

be duplicated, refer to Troubleshooting, “Power Is
Intermittently Low or Power Cutout Is Intermittent”.
Note: If the fault only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high rpm, full
load, and engine operating temperature.
Troubleshooting the symptoms under other
conditions can give misleading results.

Probable Causes
• Diagnostic codes

• Fuel supply
• Return fuel lines

• Throttle position sensor

• CAN data link

• NRS valve or intake throttle valve

• High-pressure fuel pump
• Low compression (cylinder pressure)

• Electronic unit injectors

• Individual malfunctioning cylinder

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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 M0095947-10 107
Symptom Troubleshooting

Table 58
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Codes Result: There are active codes.

A. Establish communication between the electronic service tool Repair: Troubleshoot any active codes before continuing
and the Electronic Control Module (ECM). Refer to Troubleshoot- with this procedure.
ing, “Electronic Service Tools”, if necessary.
Result: There are no active codes.
B. Download the Histograms before performing any troubleshoot-
ing or clearing any diagnostic codes. Proceed to Test Step 2.

Note: The downloaded information will be required by the Dealer

Solutions Network (DSN) if troubleshooting assistance is needed.

C. Use the electronic service tool to check for active or logged

codes.

2. Fuel Supply Fuel supply Result: There is air in the fuel system.

A. Visually check the fuel tank for fuel. The fuel gauge may be Repair: Prime the fuel system. Refer to Systems Opera-
faulty. tion, Testing, and Adjusting, “Fuel System - Prime”.

B. Ensure that the vent in the fuel cap is not filled with debris. Result: The fuel quality is not OK.

C. Ensure that the fuel supply valve (if equipped) is in the full Replace any filters and/or screens in the fuel system. Re-
OPEN position. fer to Operation and Maintenance Manual for further
information.
D. Check the primary filter/water separator for water in the fuel.
Proceed to Test Step 9.
E. Check for fuel supply or return lines that are restricted. Aged or
perished fuel lines may collapse when in service and cause tem- Result: The fuel quality is OK.
porary restrictions.
Proceed to Test Step 3.
F. Check that the Electric Priming Pump (EPP) is operating. If the
EFLP is suspect, refer to Troubleshooting, “Fuel Transfer Pump -
Test”.

G. Check for air in the fuel system. Refer to Systems Operation,

Testing and Adjusting, “Air in Fuel - Test”.

H. Obtain a fuel analysis to confirm that the correct fuel is being

used. Refer to Systems Operation, Testing and Adjusting, “Fuel
Quality - Test” for the correct procedure.

3. Throttle Position Sensor Throttle Result: The throttle position sensor response is erratic.

Note: This Test Step is only applicable if the machine has a hand Repair: Test the throttle position sensor. Refer to Trouble-
or foot throttle. shooting, “Speed Control (Analog) - Test” or Trouble-
shooting, “Speed Control (PWM) - Test”.
A. Use the electronic service tool and observe the signal for the
throttle position sensor. Make sure that the throttle response is Proceed to Test Step 9.
smooth and progressive.
Result: The throttle position sensor response is OK.

Proceed to Test Step 4.

(continued)

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 108 M0095947-10
Symptom Troubleshooting

(Table 58, contd)

Troubleshooting Test Steps Values Results
Result: The CAN data link is suspect.
4. Check the CAN Data Link Throttle
Repair: Test the CAN data link. Refer to Troubleshooting,
Note: This Test Step is only applicable if the desired engine speed “CAN Data Link - Test”.
signal is sent through the CAN data link.
Proceed to Test Step 9.
A. Use the electronic service tool to check for diagnostic codes
that are related to the CAN data link. Result: The CAN data link is OK.

Proceed to Test Step 5.

5. NRS Valve or Engine Intake Throttle Valve Pass Result: The “Air System Motor Valve Verification Test”
failed.
A. Use the electronic service tool to perform the “Air System Motor
Valve Verification Test” . Repair: Troubleshoot active diagnostic codes generated
as a result of the test.

Result: The “Air System Motor Valve Verification Test”

passed.

Proceed to Test Step 6.

6. High-Pressure Fuel Pump SCV HP fuel pump Result: The solenoid valve test fails.

A. Use the electronic service tool to perform a solenoid test on the Repair: Replace the HP fuel pump SCV and solenoid
fuel injection pump. Refer to Troubleshooting, “Solenoid Valve - assembly.
Test”.
Proceed to Test Step 9.

Result: The solenoid valve test passes successfully.

Proceed to Test Step 7.

7. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside
compression the specifications.
A. Perform a compression test. Refer to Systems Operation, Test-
ing and Adjusting, “Compression - Test”. Repair: Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown in

the following list:

· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Proceed to Test Step 9.

Result: The results of the compression test are OK.

Proceed to Test Step 8.

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 M0095947-10 109
Symptom Troubleshooting

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

NOTICE
Contact with high-pressure fuel may cause personal
injury or death. Wait 10 minutes after the engine has
stopped to allow fuel pressure to purge before any
service or repair is performed on the engine fuel
lines.

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 110 M0095947-10
Symptom Troubleshooting

Table 59
Troubleshooting Test Steps Values Results

8. Electronic Unit Injectors Electronic Unit Result: A faulty injector is indicated.

Injectors
A. Use the electronic service tool to perform the automatic “Cylin- Repair: Remove any faulty electronic unit injectors. Refer
der Cutout Test” . to Disassembly and Assembly, “Electronic Unit Injector -
Remove”.
Note: If the compression test that was performed in Test Step 7
was satisfactory, the “Cylinder Cutout Test” will identify any faulty Install new electronic unit injectors. Refer to Disassembly
injectors. and Assembly, “Electronic Unit Injector - Install”.

Repeat the automatic “Cylinder Cutout Test” . If the fault is

still apparent, remove the replacement electronic unit in-
jector and install the original electronic unit injector. Refer
to Disassembly and Assembly, “Electronic Unit Injector -
Remove” and Disassembly and Assembly, “Electronic
Unit Injector - Install”.

Proceed to Test Step 10.

Result: All injectors are OK.

Proceed to Test Step 9.

9. Check the Aftertreatment System for Oil or Fuel CEM Result The volume of drained oil or fuel is greater than
0.4 L (0.42 qt).
A. Remove excess oil or fuel from the piping with a clean cloth.
Repair: Install a replacement CEM. Refer to Disassembly
B. Remove the Clean Emissions Module (CEM). Refer to Disas- and Assembly, “Clean Emissions Module - Remove and
sembly and Assembly, “Clean Emissions Module - Remove and Install”.
Install”.
Return the unit to service.
C. Support the CEM over a suitable container with the exhaust in-
let downwards. Leave the CEM to drain for 8 hours. Result The volume of drained oil or fuel is less than 0.4 L
(0.42 qt).
D. Check the quantity of drained oil or fuel in the container.
Proceed to Test Step 10.

10. Recover the Aftertreatment System CEM Result: The “Aftertreatment Recovery Procedure” com-
pletes with a soot load of less than 80% and no smoke
A. Clean any remaining oil or fuel from the piping and the CEM in- from the exhaust.
let with a clean cloth.
Return the unit to service.
B. Install the Clean Emissions Module (CEM). Refer to Disassem-
bly and Assembly, “Clean Emissions Module - Remove and Result The “Aftertreatment Recovery Procedure” com-
Install”. pletes with a soot load of more than 80% or smoke from
the exhaust.
C. Run the engine at high idle with no load for a minimum of 20
minutes. Contact the Dealer Solutions Network (DSN).

D. Use the electronic service tool to perform the “Aftertreatment

Recovery Procedure” . While the procedure is progressing, check
for smoke from the exhaust. Some smoke will be evident during
the procedure. The smoke must dissipate before the procedure is
completed.

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 M0095947-10 111
Symptom Troubleshooting

i07707988

Engine Overcrank Occurrence

Use this procedure if the following diagnostic code is

active.

Note: The following code may not be applicable for

certain applications.

Table 60
Diagnostic Trouble Codes for Engine Overcrank Occurrence

J1939 Code Code Description Comments

The code is logged.
1664-31 Engine Automatic Start Failed
The fuel is shut off. Engine cranking is prevented.

Probable Causes
• Diagnostic codes
• Starting aids

• Load
• Battery

• Charging circuit
• Starter
• Fuel supply

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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 112 M0095947-10
Symptom Troubleshooting

Table 61
Troubleshooting Test Steps Values Results

1. Check for Associated Diagnostic Trouble Codes Diagnostic Result: No diagnostic trouble codes are active or logged.
codes
A. Establish communication between the electronic service tool Proceed to Test Step 2.
and the ECM. Refer to Troubleshooting, “Electronic Service
Tools”, if necessary. Result: Codes are active or logged.

B. Troubleshoot any diagnostic codes that are present before Repair: Troubleshoot the codes before continuing with this
continuing with this procedure. procedure.

Refer to Troubleshooting, “Diagnostic Trouble Codes” to trou-

bleshoot the diagnostic codes.

2. Starting Aids Starting aids Result: The starting aids are operating correctly.

A. If cold ambient conditions exist, check the operation of the Proceed to Test Step 3.
starting aids.
Result: The starting aids are not operating correctly.
B. Verify that the starting aids are operating correctly.
Repair: Refer to the appropriate circuit test to troubleshoot
the starting aid.

3. Excessive Loads Excessive Result: There are excessive loads on the engine.
load
A. Check for an excessive load on the engine. Repair: Reduce the load on the engine. Return the unit to
service.
B. If necessary, disengage the driven equipment and test the
engine. Result: The are not excessive loads on the engine.

Proceed to Test Step 4.

4. Battery Battery Result: The battery will no longer hold a charge.

A. Check if the battery is able to hold a charge. Refer to Systems Repair: Replace the battery. Refer to the machine Disassem-
Operation/Testing and Adjusting, “Battery - Test” for the correct bly and Assembly manual for the correct procedure.
procedure.
Result: The battery holds a charge.

Proceed to Test Step 5.

5. Switched Battery Circuit Battery circuit Result: The battery circuit is OK.

A. Inspect the battery cables, wiring, and connections in the Proceed to Test Step 6.
charging circuit.
Result: The battery circuit is not OK.
B. Check if a switched battery circuit drained the battery by
being left in the ON position. Repair: Clean all connections and tighten all connections.
Replace any faulty parts, if necessary.
C. Charge the battery. Verify that the battery is able to maintain
a charge.

(continued)

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(Table 61, contd)

Troubleshooting Test Steps Values Results

6. Alternator Alternator Result: The condition of the alternator is OK.

A. Inspect the condition of the alternator. Refer to Troubleshoot- Proceed to Test Step 7.
ing, “Alternator Problem” for the correct procedure.
Result: The condition of the alternator is not OK.

Repair: Replace or repair the alternator.

7. Starter Engagement Starter Result: The relay for the starting motor indicates that the en-
engagement gine should crank but no cranking occurs.
A. Attempt to start the engine while you observe the status of
the relay for the starting motor on the electronic service tool. Repair: Troubleshoot the starting circuit.

Result: The relay for the starting motor indicates that the en-
gine should crank and cranking occurs.

Proceed to Test Step 8.

8. Crank Cycle Crank Cycle Result: The engine cannot be cranked for enough time.

Note: A maximum of one crank cycle per overcrank is Repair: Use the electronic service tool to check the “Cycle
recommended. Crank Time” and the “Overcrank Time” parameters. The
purge cycle is part of the total crank cycle. Reprogram the pa-
A. Make sure that the engine can be cranked for enough time. rameters, if necessary.

Proceed to Test Step 9.

9. Inspection of the Fuel Supply Fuel level Result: The fuel level is not OK.

A. Visually check the fuel level in the fuel tank. Do not rely on Repair: Fill the tank.
the fuel gauge only.
If the engine has run out of fuel, purge the air from the fuel
B. Ensure that the fuel supply valve (if equipped) is in the full system. Refer to Systems Operation, Testing, and Adjusting,
OPEN position. “Fuel System - Prime”.

C. Check the fuel quality. Result: The fuel level is OK.

Make sure that the fuel meets the specification given in the Op- If the fault is still present, contact the Dealer Solutions Net-
eration and Maintenance Manual, “Fluid Recommendations”. work (DSN).

D. Inspect the fuel system.

Refer to Systems Operation, Testing, and Adjusting, “Fuel Sys-

tem” for additional information.

Cold weather adversely affects the characteristics of the fuel.

Refer to the engine Operation and Maintenance Manual, “Cold
Weather Operation” for further information.

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i08072587

Engine Overspeeds

This procedure covers the following diagnostic

trouble codes:
Table 62
Diagnostic Trouble Codes for Engine Overspeed

J1939 Code Code Description Comments

190-15 Engine Speed : High - least se- The engine has exceeded the value that is programmed into the Electronic Control Module
vere (1) (ECM) for 0.6 seconds.

There are no diagnostic trouble codes for the speed/timing sensors.

The engine has been running for at least 3 seconds.

190-0 Engine Speed : High - most se- The engine has exceeded the value that is programmed into the Electronic Control Module
vere (3) (ECM) for 0.6 seconds.

There are no diagnostic trouble codes for the speed/timing sensors.

The engine has been running for at least 3 seconds.

The engine may shut down.

The ECM limits the flow of fuel to prevent the engine

speed from exceeding the value that is programmed
into the ECM. When the engine speed has dropped
to less than the value that is programmed into the
ECM, the 190-x code will be reset.
If the engine speed exceeds the value that is
programmed into the ECM, the ECM illuminates the
warning lamp and a 190-x code is logged. Factory
passwords are required to clear the code. No
troubleshooting is required.
The history of engine overspeeds can be viewed on
the electronic service tool.

Probable Causes
• Proceeding down steep grades (if applicable)

• Diagnostic codes
• Turbocharger

• Combustible gases or liquid in the Intake air

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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Table 63
Troubleshooting Test Steps Values Results

1. Proceeding Down Steep Grades (If Applicable) Steep grades Result: Steep grades are the cause of the overspeed.

Engaging the engine brakes on a steep grade may be neces- Repair: Control the engine speed during steep grades.
sary. Not all applications have engine brakes.
Result: Steep grades are not the cause of the overspeed.
A. Make sure that the operator understands the correct oper-
ation of the machine while using the engine brakes. Proceed to Test Step 2.

2. Diagnostic Codes Diagnostic codes Result: A diagnostic code is not active or logged.

A. Download the Product Status Report with Histograms be- Return the unit to service.
fore performing any troubleshooting or clearing any diagnos-
tic codes. Result: At least one of the diagnostic codes listed in Table
62 is active or recently logged.
Note: The downloaded information will be required by the
Dealer Solutions Network (DSN) if troubleshooting assis- Proceed to Test Step 3.
tance is needed.

B. Use the electronic service tool to check for active or

logged codes.

3. Turbocharger Turbocharger Result: The turbocharger is leaking oil into the intake air.

Repair: Repair the turbocharger or replace the turbocharger.

A. Check for any oil that may be leaking into the intake air. Refer to Disassembly and Assembly, “Turbocharger - Re-
move” and Disassembly and Assembly, “Turbocharger -
Install”.

If the turbocharger is replaced, use the electronic service tool

to perform the “Turbocharger Wastegate Actuator Replace-
ment Reset” .
Use the electronic service tool to perform the “Air System
Motor Valve Verification Test”

Proceed to Test Step 5.

Result: A turbocharger is not leaking oil into the intake air.

Proceed to Test Step 4.

(continued)

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(Table 63, contd)

Troubleshooting Test Steps Values Results

4. Combustible Gases or Liquid in the Intake Air Air quality Result: The atmosphere has combustible gases.

A. Check for combustible gases in the surrounding Repair: Do not operate the engine in an environment with
atmosphere. combustible gases.

B. Check for combustible liquid in the air intake. Result: There is combustible liquid in the air intake.

C. Inspect the ether solenoid and cannister (if equipped), for Repair: Remove the liquid. Investigate and rectify the cause
leaks into the intake. of liquid ingestion

Result: The intake air does not contain combustible gases.

Contact the Dealer Solutions Network (DSN).

Result: The ether system is leaking.

Repair: Replace the ether system.

Result: The intake air does not contain combustible gases.

Contact the Dealer Solutions Network (DSN).

5. Check the Aftertreatment System for Oil CEM Result The volume of drained oil is greater than 0.4 L
(0.42 qt).
A. Remove excess oil from the piping with a clean cloth.
Repair: Install a replacement CEM. Refer to Disassembly
B. Remove the Clean Emissions Module (CEM). Refer to Dis- and Assembly, “Clean Emissions Module - Remove and
assembly and Assembly, “Clean Emissions Module - Remove Install”.
and Install”.
Return the unit to service.
C. Support the CEM over a suitable container with the ex-
haust inlet downwards. Leave the CEM to drain for 8 hours. Result The volume of drained oil is less than 0.4 L (0.42 qt).

D. Check the quantity of drained oil in the container. Proceed to Test Step 6.

6. Recover the Aftertreatment System CEM Result: The “Aftertreatment Recovery Procedure” completes
with a soot load of less than 80% and no smoke from the
A. Clean any remaining oil from the piping and the CEM inlet exhaust.
with a clean cloth.
Return the unit to service.
B. Install the Clean Emissions Module (CEM). Refer to Disas-
sembly and Assembly, “Clean Emissions Module - Remove Result The “Aftertreatment Recovery Procedure” completes
and Install”. with a soot load of more than 80% or smoke from the
exhaust.
C. Run the engine at high idle with no load for a minimum of
20 minutes. Contact the Dealer Solutions Network (DSN).

Note: During the following step, there are two versions of the
“Aftertreatment Recovery Procedure” . One version is for en-
gines with a DPF. The other version is for engines without a
DPF. Ensure that the correct procedure is used.

D. Use the electronic service tool to perform the “Aftertreat-

ment Recovery Procedure” . While the procedure is progress-
ing, check for smoke from the exhaust. Some smoke will be
evident during the procedure. The smoke must dissipate be-
fore the procedure is completed.

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i07552251

Engine Shutdown Occurs

Intermittently

Note: Use this procedure only if the engine shuts

down completely during operation.

Probable Causes
• Active codes and logged codes
• Electrical connections

• Unstable fuel supply

• Switches

• Circuit protection
• Engine speed/timing
Table 64
Associated Diagnostic Trouble Codes

J1939 Code
3719-0
3719-16
5246-0

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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Table 65
Troubleshooting Test Steps Values Results

1. Active Codes and Logged Codes Codes Result: There are associated diagnostic trouble codes active
or logged.
A. Certain diagnostic codes and/or event codes may cause an
engine shutdown. Connect the electronic service tool and check Repair: Troubleshoot any active or logged associated diag-
for active codes and for logged codes. nostic trouble codes before continuing with this procedure.

B. Use the electronic service tool to check for associated diag- Result: There are no associated diagnostic trouble codes ac-
nostic trouble codes. Refer to Table 64 tive or logged.

Proceed to Test Step 2.

2. Electrical Connections Connectors Result: There are suspect connectors.

A. Check for the correct installation of the ECM J1/P1 and the Repair: Perform the “Wiggle Test” on the electronic service
J2/P2 connectors. Check for correct installation of the fuel injec- tool.
tor connectors.
Repair or replace connectors that are suspect.

Result: There are no suspect connectors.

Proceed to Test Step 3.

3. Electrical Connections Electrical Result: The electrical connections are OK.

Connectors
A. Check the power and ground connections to the ECM. Refer Proceed to Test Step 4.
to Troubleshooting, “Electrical Power Supply - Test”.
Result: The electrical connections are not OK.

Repair: Repair or replace the damaged connectors. Verify

that the repair eliminated the fault.

4. Unstable Fuel Supply Fuel Result: The fuel quality is OK.

A. Inspect the fuel system. Refer to Systems Operation, Testing Proceed to Test Step 5.
and Adjusting, “Fuel System - Inspect” for additional information.
Result: The fuel quality is not OK.
Cold weather adversely affects the characteristics of the fuel.
Refer to the engine Operation and Maintenance Manual, “Cold Repair: Replace the fuel. Verify that the repair eliminated the
Weather Operation” for further information. fault.

B. Check fuel quality. Check the fuel tank for debris or foreign
objects which may block the fuel supply.

C. Check for air in the fuel system. Refer to Systems Operation,

Testing and Adjusting, Air in Fuel - Test.

(continued)

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Symptom Troubleshooting

(Table 65, contd)

Troubleshooting Test Steps Values Results

5. Switches Switches Result: The shutdown switches and wiring are OK.

A. Check the keyswitch input to the ECM. Proceed to Test Step 6.

B. Check any engine shutdown switches and associated wiring. Result: The shutdown switches and wiring are not OK.

Repair: Make the necessary repairs, Verify that the repair

eliminated the fault.

6. Circuit Protection Circuit Result The circuit protection device is tripped.

protection
A. Inspect the wires and connectors to all circuit protection for Repair: Reset the circuit breakers if the circuit breakers are
the engine. tripped. If necessary, replace blown fuses. Prior to returning
the engine to service, determine the condition that caused the
B. Check the device for circuit protection. circuit breaker to trip or the fuse to blow. Make the necessary
repairs.

Result The circuit protection device is OK.

Proceed to Test Step 7.

7. Engine Speed/Timing Sensors Speed/Timing Result: The Speed/Timing sensor circuit is not operating
correctly.
A. Inspect the connectors for the engine speed/timing sensors.
Repair: Test the speed/timing circuit. Refer to Troubleshoot-
B. Crank the engine. If the engine starts and no speed timing co- ing, “Speed/Timing `- Test”. Verify that the repair eliminated
des are logged, the speed timing circuit is operating correctly. the fault.

If the fault is still present, contact the Dealer Solutions Net-

work (DSN).

i07707958

Engine Shutdown While Idling

Use this procedure if one of the following codes is

active.
Table 66
J1939 Code and Description Comments
593-31 The engine has been idling for an extended amount of time.
Engine Idle Shutdown has Shut- This notification is for the operator. This notification is not a suspected engine problem.
down Engine The code is logged.

594-0 The engine is shutting down. The code is logged

Engine Idle Shutdown Driver Alert
Mode : High - most severe (3)

594-31 The engine is preparing to shut down because of an extended non-working idle time.
Engine Idle Shutdown Driver Alert The code is logged.
Mode

Probable Causes
• Extended idle time

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Recommended Actions
Table 67
Troubleshooting Test Steps Values Results

1. Engine At Idle Speed Normal Result: This condition is normal operation.

Operation
A. This condition is normal operation. The engine has been idling for Return the unit to service.
an extended amount of time and the Electronic Control Module
(ECM) will shut down the engine.

B. The “Engine Idle Shutdown Enable Status” parameter in the elec-

tronic service tool can be disabled. The amount of time before engine
shutdown can then be configured.

If the procedure did not correct the issue, contact the

Dealer Solution Network (DSN).

i08166720

Engine Stalls at Low RPM

Probable Causes
• Diagnostic codes
• Accessory equipment
• Power mode control (if equipped)

• Fuel supply
• Low compression (cylinder pressure)

• Electronic unit injectors

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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Symptom Troubleshooting

Table 68
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Diagnostic Result: A code is active or logged.

code
A. Establish communication between the electronic service tool and Repair: Troubleshoot any codes before continuing with
the Electronic Control Module (ECM) . If necessary, refer to Trouble- this procedure.
shooting, “Electronic Service Tools”.
Result: A code is not active or logged.
B. Check if any codes are active or logged.
Proceed to Test Step 2.

2. Accessory Equipment Accessories Result: An engine accessory is creating an excessive

load.
A. Check all accessory equipment for faults that may create exces-
sive load on the engine. Repair: Repair or replace the engine accessory.

Result: An engine accessory is not creating an exces-

sive load.

Proceed to Test Step 3.

3. Power Mode Control (If Equipped) Power mode Result: There is a fault in the data link.
control
A. Refer to Troubleshooting, “CAN Data Link - Test”. Repair: Repair the data link, as necessary.

B. Check the engine wiring harness for defects. Refer to Trouble- Result: There is a wiring fault.
shooting, “Electrical Connectors - Inspect”.
Repair: Repair or replace the wiring, as necessary.

Result: The data link and the wiring are OK.

Proceed to Test Step 4.

(continued)

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(Table 68, contd)

Troubleshooting Test Steps Values Results

4. Fuel Supply Fuel system Result: The vent in the fuel cap is blocked.

A. Ensure that the vent in the fuel cap is not filled with debris. Repair: Install a replacement fuel cap.

B. Ensure that the fuel supply valve (if equipped) is in the full OPEN Result: The fuel contains solidified wax.
position.
Repair: Replace the fuel with fuel of the correct specifi-
C. If the temperature is below 0 °C (32 °F), check for solidified fuel cation for the ambient conditions.
(wax).
Result: There are fuel supply lines that are restricted.
D. Check the primary filter/water separator for water in the fuel.
Repair: Replace any damaged or restricted fuel lines.
E. Check for fuel supply lines that are restricted.
The EFLP is suspect. Refer to Troubleshooting, “Fuel
F. Replace the in-line fuel filter that is installed upstream of the Elec- Transfer Pump - Test”.
tric Priming Pump (EPP).
Replace any filters and/or screens in the fuel system. Re-
G. Check that the EPP is operating correctly. fer to Operation and Maintenance Manual for further
information.
H.Replace any filters and/or screens in the fuel system. Refer to
Operation and Maintenance Manual for further information. Result: There is air in the fuel system.

I. Check the diesel fuel for contamination. Refer to Systems Opera- Repair: Prime the fuel system. Refer to Systems Opera-
tion, Testing, and Adjusting, “Fuel Quality - Test”. tion, Testing, and Adjusting, “Fuel System - Prime”.

J. Check for air in the fuel system. Refer to Systems Operation, Result: The diesel fuel is contaminated.
Testing, and Adjusting, “Air in Fuel - Test”.
Repair: Drain the fuel tank and the fuel system.

Replace any filters and/or screens in the fuel system. Re-

fer to Operation and Maintenance Manual for further
information.

Fill and prime the fuel system with fuel of the correct
specification. Refer to Systems Operation, Testing, and
Adjusting, “Fuel System - Prime”.

Result: The fuel supply is OK.

Proceed to Test Step 5.

5. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside
compression the specifications.
A. Perform a compression test. Refer to Systems Operation, Test-
ing, and Adjusting, “Compression - Test”. Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown in

the following list:

· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Result: The results of the compression test are OK.

(continued)

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Symptom Troubleshooting

(Table 68, contd)

Troubleshooting Test Steps Values Results

Proceed to Test Step 6.

6. Electronic Unit Injectors Electronic Unit Result: A faulty injector is indicated.

Injectors
A. Use the electronic service tool to perform the automatic “Cylinder Repair: Remove any faulty electronic unit injectors. Re-
Cutout Test” . fer to Disassembly and Assembly, “Electronic Unit Injec-
tor - Remove”.
Note: If the compression test that was performed in Test Step 5 was
satisfactory, the “Cylinder Cutout Test” will identify any faulty Install new electronic unit injectors. Refer to Disassembly
injectors. and Assembly, “Electronic Unit Injector - Install”.

Repeat the automatic “Cylinder Cutout Test” . If the fault

is still apparent, remove the replacement electronic unit
injector and install the original electronic unit injector. Re-
fer to Disassembly and Assembly, “Electronic Unit Injec-
tor - Remove” and Disassembly and Assembly,
“Electronic Unit Injector - Install”.

Result: All injectors are OK.

Contact the Dealer Solutions Network (DSN).

i08166722 • Electronic unit injectors

Engine Top Speed Is Not • Individual malfunctioning cylinders

Obtained Table 69
Associated Diagnostic Trouble Codes

J1939 Code
Note: If this fault occurs only under load, refer to
157-18
Troubleshooting, “Acceleration Is Poor or Throttle
Response Is Poor”.
Recommended Actions
Probable Causes
Note: The procedures have been listed in order of
• Diagnostic codes probability. Complete the procedures in order.
• ECM parameters
• Accessory and/or parasitic loads
• Flash file

• Throttle signal
• Air intake and exhaust system

• Turbocharger
• Fuel supply

• Electric Fuel Lift Pump (EFLP)

• Return fuel lines

• Low compression (cylinder pressure)

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Table 70
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Diagnostic Result: There are active or logged codes.

codes
A. Establish communication between the electronic service Repair: Troubleshoot any codes before continuing with this
tool and the Electronic Control Module (ECM). Refer to Trou- procedure.
bleshooting, “Electronic Service Tools”, if necessary.
Result: There are no active or logged codes.

B. Use the electronic service tool to check for active or logged Proceed to Test Step 2.
codes.

2. ECM Parameters Parameters Result: The parameters are not configured correctly.

A. Use the electronic service tool to verify that the correct en- Repair: Correctly configure the parameters.
gine parameters are being used. Refer to Troubleshooting,
“Configuration Parameters” for additional information. Verify that the configuration change eliminated the fault.

B. If applicable, verify that all parameters for any parasitic Result: The parameters are configured correctly.
loads are correct.
Proceed to Test Step 3.

3. Accessory and/or Parasitic Loads Parasitic loads Result: There is an excessive load on the engine.

A. Check all accessory equipment for problems that may cre- Repair: Diagnose and repair the fault.
ate excessive load on the engine.
Verify that the repair eliminated the fault.
B. Check for any excess parasitic load on the engine.
Result: There is not an excessive load on the engine.

Proceed to Test Step 4.

4. Flash File Flash file Result: The latest flash file is not installed in the ECM.

A. Verify that the latest flash file is installed in the Electronic Repair: Install the latest flash file. Verify that the repair elimi-
Control Module (ECM). Refer to Troubleshooting, “ECM Soft- nated the fault.
ware - Install” for the correct procedure.
Result: The latest flash file is installed in the ECM.

Proceed to Test Step 5.

5. Throttle Signal CAN data link Result: The throttle signal is erratic or does not reach the
100% raw position or the calibrated position.
A. Use the electronic service tool and observe the throttle sig-
nal. Make sure that the throttle reaches the 100% raw posi- Repair: Refer to the appropriate circuit test for the type of
tion and the calibrated position. throttle that is installed.

Result: The throttle signal is OK.

Proceed to Test Step 6.

(continued)

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(Table 70, contd)

Troubleshooting Test Steps Values Results

6. Air Intake and Exhaust System Restrictions Result: The air filter is plugged.

A. Check the air filter restriction indicator, if equipped. Repair: Clean or replace the air filter. Refer to the Operation
and Maintenance Manual for further information.
B. Check the air inlet and exhaust system for restrictions and/
or leaks. Result: There are restrictions in the air inlet or exhaust
system.

Repair: Make the necessary repairs, Verify that the repair

eliminated the fault.

Result: There are no restrictions in the air inlet or exhaust

system.

Proceed to Test Step 7.

7. Turbocharger Turbocharger Result: The turbocharger is not operating correctly.

A. Check for the correct operation of the turbocharger. Repair: Repair or replace the faulty turbocharger. Verify that
the repair eliminated the fault.

If the turbocharger is replaced, use the electronic service tool

to perform the “Turbocharger Wastegate Actuator Replace-
ment Reset” .
Use the electronic service tool to perform the “Air System Mo-
tor Valve Verification Test”

Result: The turbocharger is operating correctly.

Proceed to Test Step 8.

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

NOTICE
Contact with high-pressure fuel may cause personal
injury or death. Wait 10 minutes after the engine has
stopped to allow fuel pressure to purge before any
service or repair is performed on the engine fuel
lines.

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Table 71
Troubleshooting Test Steps Values Results

8. Fuel Supply Fuel system Result: There is a leak from a high-pressure fuel line.

A. Check for leaks from the high-pressure fuel lines. Repair: Replace the high-pressure fuel line. Refer to Disas-
sembly and Assembly, “Fuel injection lines - Remove” and
B. Ensure that the vent in the fuel cap is not filled with debris. Disassembly and Assembly, “Fuel injection lines - Install”.

C. Ensure that the fuel supply valve (if equipped) is in the full Result: The vent in the fuel cap is blocked.
OPEN position.
Repair: Install a replacement fuel cap.
D. If the temperature is below 0 °C (32 °F), check for solidi-
fied fuel (wax). Result: The fuel contains solidified wax.

E. Check the primary filter/water separator for water in the Repair: Replace the fuel with fuel of the correct specification
fuel. for the ambient conditions.

F. Check for fuel supply lines that are restricted. Result: There are fuel supply lines that are restricted.

G. Replace the in-line fuel filter that is installed upstream of Repair: Replace any damaged or restricted fuel lines.
the Electric Priming Pump (EPP).
Replace any filters and/or screens in the fuel system. Refer to
H. Replace any filters and/or screens in the fuel system. Re- Operation and Maintenance Manual for further information.
fer to Operation and Maintenance Manual for further Result: There is air in the fuel system.
information.
Repair: Prime the fuel system. Refer to Systems Operation,
I. Check the diesel fuel for contamination. Refer to Systems Testing, and Adjusting, “Fuel System - Prime”.
Operation, Testing, and Adjusting, “Fuel Quality - Test”.
Result: The diesel fuel is contaminated.
J. Check for air in the fuel system. Refer to Systems Opera-
tion, Testing, and Adjusting, “Air in Fuel - Test”. Repair: Drain the fuel tank and the fuel system.

Replace any filters and/or screens in the fuel system. Refer to

Operation and Maintenance Manual for further information.
Fill and prime the fuel system with fuel of the correct specifica-
tion. Refer to Systems Operation, Testing, and Adjusting,
“Fuel System - Prime”.

Result: The fuel supply is OK.

Proceed to Test Step 9.

9. Check the Return Fuel Lines Return lines Result: The fuel return lines are blocked or kinked.

A. Make sure that the fuel return lines are not blocked or Repair: Clear or replace the blocked line.
kinked.
Result: The fuel return lines are clear.

Repair: Proceed to Test Step 10.

(continued)

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Symptom Troubleshooting

(Table 71, contd)

Troubleshooting Test Steps Values Results

10. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside the
compression specifications.
A. Perform a compression test. Refer to Systems Operation,
Testing, and Adjusting, “Compression - Test”. Repair: Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown in the

following list:

· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Result: The results of the compression test are OK.

Proceed to Test Step 11.

11. Electronic Unit Injectors Electronic Unit Result: A faulty injector is indicated.
Injectors
A. Use the electronic service tool to perform the automatic Repair: Remove any faulty electronic unit injectors. Refer to
“Cylinder Cutout Test” . Disassembly and Assembly, “Electronic Unit Injector -
Remove”.
Note: If the compression test that was performed in Test Step
10 was satisfactory, the “Cylinder Cutout Test” will identify Install new electronic unit injectors. Refer to Disassembly and
any faulty injectors. Assembly, “Electronic Unit Injector - Install”.

Repeat the automatic “Cylinder Cutout Test” . If the fault is still

apparent, remove the replacement electronic unit injector and
install the original electronic unit injector. Refer to Disassem-
bly and Assembly, “Electronic Unit Injector - Remove” and Dis-
assembly and Assembly, “Electronic Unit Injector - Install”.

Result: All injectors are OK.

Proceed to Test Step 12.

12. Individual Malfunctioning Cylinders Cylinders Result: The test indicates a faulty cylinder.

A. With the engine speed at a fast idle, use the electronic Repair: Investigate the cause of the fault on any cylinder that
service tool to perform the manual “Cylinder Cutout Test” . is not operating. Investigate the cause of the fault on any cylin-
der that is operating below normal performance.
As each cylinder is cut out, listen for a change in the sound
from the engine. When a cylinder is cut out, there should be a Result: The test indicates that all cylinders are OK.
noticeable change in the sound of the engine.
Contact the Dealer Solutions Network (DSN).
Note: If a change in the sound of the engine is not noted, the
isolated cylinder is not operating under normal conditions. If
the isolation of a cylinder results in a change in the sound that
is less noticeable, the cylinder may be operating below nor-
mal performance.

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 128 M0095947-10
Symptom Troubleshooting

i07715447

Engine Vibration Is Excessive

Refer to Systems Operation, Testing and Adjusting

for additional information on determining the cause of
this condition.

Probable Causes
• Driven equipment
• Engine supports

• Low compression (cylinder pressure)

• Electronic unit injectors

• Individual malfunctioning cylinder

Recommended Actions
Note: When performing the following procedure, do
not stand near the engine. The vibration may indicate
an imminent component failure.

Note: Complete the procedure in the order in which

the steps are listed.

Table 72
Troubleshooting Test Steps Values Results

1. Driven Equipment Driven Result The driven equipment and the alignment are not
equipment OK.
A. Inspect the mounting bolts for the driven equipment. Inspect the
alignment and the balance of the driven equipment. Repair: Repair or replace the driven equipment.

B. Inspect the coupling. Result: The driven equipment and the alignment are OK.

Proceed to Test Step 2.

2. Engine Supports Engine Result: The mounts and brackets are loose and/or
supports broken.
A. Inspect the mounts and the brackets while you run the engine
through the speed range. Look for mounts and brackets that are Replace the mounts and brackets that are loose and/or
loose and/or broken. broken.

B. Check the alignment of the following before operating the en- Result: The mounts and brackets are not loose and/or
gine under load for any length of time: broken.

· Mounts Proceed to Test Step 3.

· Coupling

(continued)

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 M0095947-10 129
Symptom Troubleshooting

(Table 72, contd)

Troubleshooting Test Steps Values Results

3. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside
compression the specifications.
A. Perform a compression test. Refer to Systems Operation, Test-
ing, and Adjusting, “Compression - Test”. Repair: Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown in

the following list:

· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Result: The results of the compression test are OK.

Proceed to Test Step 4.

4. Electronic Unit Injectors Electronic Unit Result: A faulty injector is indicated.

Injectors
A. Use the electronic service tool to perform the automatic “Cylin- Repair: Remove any faulty electronic unit injectors. Refer
der Cutout Test” . to Disassembly and Assembly, “Electronic Unit Injector -
Remove”.
Note: If the compression test that was performed in Test Step 3
was satisfactory, the “Cylinder Cutout Test” will identify any faulty Install new electronic unit injectors. Refer to Disassembly
injectors. and Assembly, “Electronic Unit Injector - Install”.

Repeat the automatic “Cylinder Cutout Test” . If the fault is

still apparent, remove the replacement electronic unit in-
jector and install the original electronic unit injector. Refer
to Disassembly and Assembly, “Electronic Unit Injector -
Remove” and Disassembly and Assembly, “Electronic Unit
Injector - Install”.

Result: All injectors are OK.

Proceed to Test Step 5.

5. Individual Malfunctioning Cylinders Cylinders Result: The test indicates a faulty cylinder.

A. With the engine speed at a fast idle, use the electronic service Repair: Investigate the cause of the fault on any cylinder
tool to perform the manual “Cylinder Cutout Test” . that is not operating. Investigate the cause of the fault on
any cylinder that is operating below normal performance.
As each cylinder is cut out, listen for a change in the sound from
the engine. When a cylinder is cut out, there should be a notice- Result: The test indicates that all cylinders are OK.
able change in the sound of the engine.
Contact the Dealer Solutions Network (DSN).
Note: If a change in the sound of the engine is not noted, the iso-
lated cylinder is not operating under normal conditions. If the isola-
tion of a cylinder results in a change in the sound that is less
noticeable, the cylinder may be operating below normal
performance.

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 130 M0095947-10
Symptom Troubleshooting

i08072621

Exhaust Has Excessive Black

Smoke

If excessive black smoke is caused by an engine

fault, the smoke will only be visible when the Diesel
Particulate Filter (DPF) has also failed. Perform the
following procedure to diagnose the cause of the
black smoke and then investigate the failure of the
DPF.
Note: A faulty DPF will allow some smoke to be
visible. In this situation, there may not be a fault in the
engine.

Probable Causes
• Diagnostic codes
• Parameters in the Electronic Control Module
(ECM)
• Air intake system or exhaust system

• NRS Valve
• Valve lash
• Turbocharger

• Low compression (cylinder pressure)

• Electronic unit injectors

• Individual malfunctioning cylinder

Recommended Actions
Note: Complete the procedure in the order in which
the steps are listed.

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 M0095947-10 131
Symptom Troubleshooting

Table 73
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Diagnostic Result: A diagnostic code is present.

codes
A. Download Histograms before performing any troubleshoot- Repair: Troubleshoot the code.
ing or clearing any diagnostic codes.
Result: A diagnostic code is not present.
Note: The downloaded information will be required by the Proceed to Test Step 2.
Dealer Solutions Network (DSN) if troubleshooting assistance
is needed.

B. Use the electronic service tool to check for active or logged

codes.

2. Parameters in the Electronic Control Module (ECM) Parameters Result: The parameters are not correct.

A. Use the electronic service tool to verify that the correct pa- Repair: Input the correct parameters. Refer to Troubleshoot-
rameters are being used. Refer to Troubleshooting, “Configu- ing, “Configuration Parameters” for additional information.
ration Parameters” for additional information.
Result: The parameters are correct.

Proceed to Test Step 3.

3. Air Intake and Exhaust System Restrictions Result: There are restrictions in the air inlet or exhaust
system.
A. Observe the check engine lamp. Check for an air filter re-
striction indicator, if equipped. Replace a plugged air filters. Repair: Make the necessary repairs, Refer to Systems Oper-
Refer to the Operation and Maintenance Manual. ation, Testing and Adjusting, “Air Inlet and Exhaust System -
Inspect” for additional information.
B. Check the air inlet and exhaust system for restrictions and/
or leaks. Result: There are no restrictions in the air inlet or exhaust
system.

Proceed to Test Step 4.

4. NRS Valve Pass Result: The “Air System Motor Valve Verification Test” failed.

A. Use the electronic service tool to perform the “Air System Repair: Troubleshoot active diagnostic codes generated as a
Motor Valve Verification Test” . result of the test.

Result: The “Air System Motor Valve Verification Test”

passed.

Proceed to Test Step 5.

5. Valve Lash Valve lash Result: The valve lash is incorrect.

A. Check the valve lash. Repair: Check the valve lash. Refer to Systems Operation,
Testing, and Adjusting, “Engine Valve Lash - Inspect” for the
correct procedure.

Result: The valve lash is correct.

Proceed to Test Step 6.

(continued)

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Symptom Troubleshooting

(Table 73, contd)

Troubleshooting Test Steps Values Results

6. Turbocharger Turbocharger Result: There is a fault in the turbocharger.

A. Ensure that the mounting bolts for the turbocharger are Repair: Repair the turbocharger or replace the turbocharger.
tight. Refer to Disassembly and Assembly, “Turbocharger - Re-
move” and Disassembly and Assembly, “Turbocharger -
B. Check that the oil drain for the turbocharger is not blocked Install”.
or restricted.
If the turbocharger is replaced, use the electronic service tool
C. Check that the compressor housing for the turbocharger is to perform the “Turbocharger Wastegate Actuator Replace-
free of dirt and debris. Make sure that the housing is not ment Reset” .
damaged. Use the electronic service tool to perform the “Air System Mo-
tor Valve Verification Test”
D. Check that the turbine housing for the turbocharger is free
of dirt and debris. Make sure that the housing is not damaged. Result: The turbocharger is OK.

E. Check that the turbine blades rotate freely in the Proceed to Test Step 7.
turbocharger.

F. Ensure that the wastegate on the turbocharger is operating

correctly. Refer to Systems Operation, Testing, and Adjusting,
“Turbocharger - Inspect”. If the wastegate actuator is faulty, re-
place the turbocharger. Refer to Disassembly and Assembly,
“Turbocharger - Remove” and Disassembly and Assembly,
“Turbocharger - Install”.

If the turbocharger is replaced, use the electronic service tool

to perform the “Turbocharger Wastegate Actuator Replace-
ment Reset” .
Use the electronic service tool to perform the “Air System Mo-
tor Valve Verification Test”

7. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside the
compression specifications.
A. Perform a compression test. Refer to Systems Operation,
Testing, and Adjusting, “Compression - Test”. Repair: Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown in the

following list:

· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Result: The results of the compression test are OK.

Proceed to Test Step 8.

NOTICE
Contact with high-pressure fuel may cause personal
Contact with high pressure fuel may cause fluid injury or death. Wait 10 minutes after the engine has
penetration and burn hazards. High pressure fuel stopped to allow fuel pressure to purge before any
spray may cause a fire hazard. Failure to follow service or repair is performed on the engine fuel
these inspection, maintenance and service in- lines.
structions may cause personal injury or death.

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 M0095947-10 133
Symptom Troubleshooting

Table 74
Troubleshooting Test Steps Values Results

8. Electronic Unit Injectors Electronic Unit Result: A faulty injector is indicated.

Injectors
A. Use the electronic service tool to perform the automatic Repair: Remove any faulty electronic unit injectors. Refer to
“Cylinder Cut Out Test” . Disassembly and Assembly, “Electronic Unit Injector -
Remove”.
Note: If the compression test that was performed in Test Step
7 was satisfactory, the “Cylinder Cut Out Test” will identify any Install new electronic unit injectors. Refer to Disassembly
faulty injectors. and Assembly, “Electronic Unit Injector - Install”.

Repeat the automatic “Cylinder Cut Out Test” . If the fault is

still apparent, remove the replacement electronic unit injector
and install the original electronic unit injector. Refer to Disas-
sembly and Assembly, “Electronic Unit Injector - Remove”
and Disassembly and Assembly, “Electronic Unit Injector -
Install”.

Result: All injectors are OK.

Proceed to Test Step 9.

9. Individual Malfunctioning Cylinders Cylinders Result: The test indicates a faulty cylinder.

A. With the engine speed at a fast idle, use the electronic serv- Repair: Investigate the cause of the fault on any cylinder that
ice tool to perform the manual “Cylinder Cut Out Test” . is not operating. Investigate the cause of the fault on any cyl-
inder that is operating below normal performance.
As each cylinder is cut out, listen for a change in the sound
from the engine. When a cylinder is cut out, there should be a Result: The test indicates that all cylinders are OK.
noticeable change in the sound of the engine.
Contact the Dealer Solutions Network (DSN).
If a change in the sound of the engine is not noted, the isolated
cylinder is not operating under normal conditions. If the isola-
tion of a cylinder results in a change in the sound that is less
noticeable, the cylinder may be operating below normal
performance.

i08016663 • Cooling system

Exhaust Has Excessive White • Fuel quality

Smoke • Valve lash

• Low compression (cylinder pressure)

Note: Some white smoke may be present during cold • Electronic unit injectors
start-up conditions and during acceleration after a
prolonged period at low idle. If the white smoke • Individual malfunctioning cylinder
persists, there may be a fault. • Aftertreatment system contains oil or fuel

Probable Causes Recommended Actions

• Diagnostic codes
Diagnostic Codes
• ECM Flash file
Note: The procedures have been listed in order of
• Glow plugs probability. Complete the procedures in order.
• Ether injection
• Coolant temperature

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 134 M0095947-10
Symptom Troubleshooting

Table 75
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Diagnostic codes Result: A code is active or logged.

A. Establish communication between the electronic service tool Repair: Troubleshoot any active codes before continu-
and the Electronic Control Module (ECM) . Refer to Troubleshoot- ing with this procedure.
ing, “Electronic Service Tools”, if necessary.
B. Download the Histograms before performing any troubleshoot- Result: A code is not active or logged.
ing or clearing any diagnostic codes.
Proceed to Test Step 2.
Note: The downloaded information will be required by the Dealer
Solutions Network (DSN) if troubleshooting assistance is needed.

C. Determine if a code is active or logged.

2. ECM Flash File Flash file Result: The latest flash file is not installed.

A. Verify that the latest flash file is installed in the ECM. Repair: Install the latest flash file. Refer to Trouble-
shooting, “ECM Software - Install” for the correct proce-
dure. Verify that the repair eliminates the fault.

Result: The latest flash file is installed.

Proceed to Test Step 3.

3. Glow Plugs Glow plugs Result: The glow plugs are not operating correctly.

Note: Faulty glow plugs will only affect the production of white Repair: Make the necessary repairs. Verify that the re-
smoke when the ambient temperature is between 5° C (41° F) pair corrected the fault.
and −25° C (−13° F).
Result: The glow plugs are operating correctly.
A. Check operation of glow plugs. Verify that the glow plugs are
operating correctly. Refer to Troubleshooting, “Glow Plug Starting Proceed to Test Step 4.
Aid - Test”.

B. Check the configuration screen on the electronic service tool to

verify that ether injection is not enabled.

4. Ether Injection Glow plugs Result: The ether starting aid is faulty.

Note: A faulty ether starting aid will only affect the production of Repair: Test the ether system. Refer to Troubleshoot-
white smoke when the ambient temperature is below −25° C ing, “Ether Starting Aid - Test”.
(−13° F).
Result: The ether starting aid is operating correctly.
A. Use the electronic service tool to test the ether starting aid.
Proceed to Test Step 5.

(continued)

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 M0095947-10 135
Symptom Troubleshooting

(Table 75, contd)

Troubleshooting Test Steps Values Results

5. Coolant Temperature Coolant Result: The water temperature regulator is not operat-
temperature ing correctly.
A. Check that the water temperature regulator is operating cor-
rectly. Refer to Systems Operation, Testing, and Adjusting, “Water Repair: Replace the water temperature regulator. Veri-
Temperature Regulator - Test”. fy that the repair corrected the fault.

Result: The water temperature regulator is operating

correctly.

Proceed to Test Step 6.

6. Cooling System Internal coolant Result: There is an internal coolant leak.

leak
A. Check for an internal coolant leak into the cylinder and/or the Repair: Make the necessary repairs. Verify that the re-
exhaust. Refer to Systems Operation/Testing and Adjusting, pair eliminated the fault.
“Cooling System”.
Result: There is not an internal coolant leak.

Proceed to Test Step 7.

7. Fuel Quality Fuel Result: The fuel quality is not OK.

A. Check the fuel quality. Refer to Systems Operation, Testing, Repair: Drain the fuel system and replace the fuel fil-
and Adjusting, “Fuel Quality - Test”. ters. Refer to the Operation and Maintenance Manual,
“Fuel System Primary Filter (Water Separator) Element
B. Refer to Operation and Maintenance Manual for information on - Replace” and Operation and Maintenance Manual,
the proper characteristics of the fuel for the engine. “Fuel System Filter - Replace”.

Fill the fuel system with fuel that meets the standard in
the Operation and Maintenance Manual, “Fluid
Recommendations”.

Prime the fuel system. Refer to the Operation and

Maintenance Manual, “Fuel System - Prime”.

Proceed to Test Step 12.

Result: The fuel quality is OK.

Proceed to Test Step 8.

8. Valve Lash Valve lash Result: The valve lash is not set correctly.

Note: The valve lash can affect the performance of the engine. Repair: Check the valve lash. Refer to Systems Opera-
A. Check the valve lash. tion, Testing, and Adjusting, “Engine Valve Lash - In-
spect” for the correct procedure.

Proceed to Test Step 12.

Result: The valve lash is correct.

Proceed to Test Step 9.

(continued)

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 136 M0095947-10
Symptom Troubleshooting

(Table 75, contd)

Troubleshooting Test Steps Values Results

9. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside
compression the specifications.
A. Perform a compression test. Refer to Systems Operation, Test-
ing, and Adjusting, “Compression - Test”. Repair: Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown

in the following list:

· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Proceed to Test Step 12.

Result: The results of the compression test are OK.

Proceed to Test Step 10.

10. Electronic Unit Injectors Electronic Unit Result: A faulty injector is indicated.
Injectors
A. Use the electronic service tool to perform the automatic “Cylin- Repair: Remove any faulty electronic unit injectors.
der Cutout Test” . Refer to Disassembly and Assembly, “Electronic Unit
Injector - Remove”.
Note: If the compression test that was performed in Test Step 9
was satisfactory, the “Cylinder Cutout Test” will identify any faulty Install new electronic unit injectors. Refer to Disassem-
injectors. bly and Assembly, “Electronic Unit Injector - Install”.

Repeat the automatic “Cylinder Cutout Test” . If the

fault is still apparent, remove the replacement elec-
tronic unit injector and install the original electronic unit
injector. Refer to Disassembly and Assembly, “Elec-
tronic Unit Injector - Remove” and Disassembly and
Assembly, “Electronic Unit Injector - Install”.

Proceed to Test Step 12.

Result: All injectors are OK.

Proceed to Test Step 11.

(continued)

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 M0095947-10 137
Symptom Troubleshooting

(Table 75, contd)

Troubleshooting Test Steps Values Results

11. Individual Malfunctioning Cylinders Cylinders Result: The test indicates a faulty cylinder.

A. With the engine speed at a fast idle, use the electronic service Repair: Investigate the cause of the fault on any cylin-
tool to perform the manual “Cylinder Cutout Test” . der that is not operating. Investigate the cause of the
fault on any cylinder that is operating below normal
As each cylinder is cut out, listen for a change in the sound from performance.
the engine. When a cylinder is cut out, there should be a notice-
able change in the sound of the engine. Proceed to Test Step 12.

If a change in the sound of the engine is not noted, the isolated cyl- Result: The test indicates that all cylinders are OK.
inder is not operating under normal conditions. If the isolation of a
cylinder results in a change in the sound that is less noticeable, Contact the Dealer Solutions Network (DSN).
the cylinder may be operating below normal performance.

12. Check the Aftertreatment System for Oil or Fuel CEM Result The volume of drained oil or fuel is greater than
0.4 L (0.42 qt).
A. Remove excess oil or fuel from the piping with a clean cloth.
Repair: Install a replacement CEM. Refer to Disassem-
B. Remove the Clean Emissions Module (CEM). Refer to Disas- bly and Assembly, “Clean Emissions Module - Remove
sembly and Assembly, “Clean Emissions Module - Remove and and Install”.
Install”.
Return the unit to service.
C. Support the CEM over a suitable container with the exhaust in-
let downwards. Leave the CEM to drain for 8 hours. Result The volume of drained oil or fuel is less than
0.4 L (0.42 qt).
D. Check the quantity of drained oil or fuel in the container.
Proceed to Test Step 13.

13. Recover the Aftertreatment System CEM Result: The “Aftertreatment Recovery Procedure”
completes with a soot load of less than 80% and no
A. Clean any remaining oil or fuel from the piping and the CEM in- smoke from the exhaust.
let with a clean cloth.
Return the unit to service.
B. Install the Clean Emissions Module (CEM). Refer to Disassem-
bly and Assembly, “Clean Emissions Module - Remove and Result The “Aftertreatment Recovery Procedure” com-
Install”. pletes with a soot load of more than 80% or smoke
from the exhaust.
C. Run the engine at high idle with no load for a minimum of 20
minutes. Contact the Dealer Solutions Network (DSN).

D. Use the electronic service tool to perform the “Aftertreatment

Recovery Procedure” . While the procedure is progressing, check
for smoke from the exhaust. Some smoke will be evident during
the procedure. The smoke must dissipate before the procedure is
completed.

i07561742 Probable Causes

Exhaust System Contains • NOx Reduction System (NRS) cooler
Coolant • Cylinder head gasket
• Cylinder head
Use the following procedure to troubleshoot a • Cylinder block
problem with coolant in the exhaust system.

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 138 M0095947-10
Symptom Troubleshooting

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Note: After the repair has been made, the electronic
service tool must be used to perform an
“Aftertreatment System Functional Test” . The test
will verify the correct functionality of both NOx
sensors and the catalysts.

Table 76
Troubleshooting Test Steps Values Results

1. NRS cooler NRS cooler Result : The NRS cooler has a leak.

A. Check the NRS cooler for leaks. Refer to Systems Opera- Repair: Replace the NRS cooler. Refer to the Disassembly
tion, Testing, and Adjusting, “Exhaust Cooler (NRS) - Test”. and Assembly manual for the correct procedure.

Proceed to Step 5.

Result : The NRS cooler does not have a leak.

Proceed to Test Step 2.

2. Cylinder head gasket leak Cylinder head Result : The cylinder head gasket is leaking.
gasket
A. Check the cylinder head gasket for leaks. Proceed to Test Step 3.

Result : The cylinder head gasket is not leaking.

Proceed to Test Step 3.

3. Cylinder head Cylinder head Result : A crack is found in the cylinder head.

A. Check for cracks in the cylinder head. Perform a leak test Repair: Repair the cylinder head or replace the cylinder head.
on the cylinder head. Refer to the Systems Operation, Testing, Refer to the Disassembly and Assembly manual.
and Adjusting, “Cylinder Head - Inspect” for the correct
procedure. Proceed to Test Step 4.

Result : The cylinder head is OK.

Proceed to Test Step 4.

(continued)

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 M0095947-10 139
Symptom Troubleshooting

(Table 76, contd)

Troubleshooting Test Steps Values Results

4. Cylinder Block Cylinder head Result : A crack is found in the cylinder block.

A. Check for cracks in top face of the cylinder block. Refer to Repair: Repair the cylinder block or replace the cylinder
the Systems Operation, Testing, and Adjusting, “Cylinder block. Refer to the Disassembly and Assembly manual.
Block - Inspect” for the correct procedure.
Repair: Assemble the cylinder head with a new cylinder head
gasket. Refer to the Disassembly and Assembly manual.

Proceed to Test Step 5.

Result : The cylinder block is OK.

Repair: Assemble the cylinder head with a new cylinder head

gasket. Refer to the Disassembly and Assembly manual.

Proceed to Test Step 5.

5. Perform an “ Aftertreatment System Functional Test”” System test Result : The test is successful.

A. Start the engine. Return the engine to service.

B. Connect the electronic service tool to the diagnostic Result : The test is not successful.
connector.
There are diagnostic codes.
C. Navigate to “Diagnostics Tests” .
Repair: Troubleshoot the additional codes. Refer to Trouble-
D. Perform the “Aftertreatment System Functional Test” . shooting, “Diagnostic Trouble Codes” manual for the correct
procedure.

i08072899

Exhaust System Contains Oil

Probable Causes
• Extended idle times
• Failed turbocharger seals

• Worn valve guide seals or faulty valve guide seals

• Worn valve guides
• Worn piston rings
Complete the procedure in the order in which the
steps are listed.

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 140 M0095947-10
Symptom Troubleshooting

Table 77
Troubleshooting Test Steps Values Results

1. Extended Idle Times Idle times Result The idle times are extensive.

A. Extended idle times will allow oil to pass into the exhaust Reduce the idle times.
system.
Proceed to Test Step 6.

Result The idle times are not extensive.

Proceed to Test Step 2.

2. Failed Turbocharger Seals Turbo seals Result: Oil is present in the inlet or exhaust manifold.

A. Check the inlet manifold and the exhaust manifold for oil. Repair: Replace the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Remove” and Disassembly
and Assembly, “Turbocharger - Install”.

If the turbocharger is replaced, use the electronic service

tool to perform the “Turbocharger Wastegate Actuator Re-
placement Reset” .
Use the electronic service tool to perform the “Air System
Motor Valve Verification Test”

Proceed to Test Step 6.

Result: Oil is not present in the inlet or exhaust manifold.

Proceed to Test Step 3.

3. Worn Valve Guide Seals or Faulty Valve Guide Seals Valve guide Result: The valve guide seals are damaged.
seals
A. Inspect the valve guide seals for wear and for damage. Repair: Replace the valve guide seals. Verify the repair.

Proceed to Test Step 6.

Result: The valve guide seals are not damaged.

Proceed to Test Step 4.

4. Worn Valve Guides Valve guides Result: The valve guides are worn.

A. Inspect the valve guides for wear. Refer to the Specification Repair: If necessary, recondition the cylinder head. Verify
manual for the maximum permissible wear of the valve guides. the repair.

Proceed to Test Step 6.

Result: The valve guides are not worn.

Proceed to Test Step 5.

(continued)

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Symptom Troubleshooting

(Table 77, contd)

Troubleshooting Test Steps Values Results

5. Worn Piston Rings Piston rings Result The piston rings are worn.

A. Remove the pistons. Refer to Disassembly and Assembly, “Pis- Repair: Replace the piston rings. Verify the repair.
tons and Connecting Rods - Remove”.
Proceed to Test Step 6.
B. Remove the piston rings from the pistons. Refer to Disassembly
and Assembly, “Pistons and Connecting Rods - Disassemble” Result The piston rings are not worn.

C. Inspect the pistons and piston rings for wear or damage. Refer Contact the Dealer Solutions Network (DSN).
to the “Specifications” manual for further information.

6. Check the Aftertreatment System for Oil CEM Result The volume of drained oil is greater than 0.4 L
(0.42 qt).
A. Remove excess oil from piping with a clean cloth.
Repair: Install a replacement CEM. Refer to Disassembly
B. Remove the Clean Emissions Module (CEM). Refer to Disas- and Assembly, “Clean Emissions Module - Remove and
sembly and Assembly, “Clean Emissions Module - Remove and Install”.
Install”.
Return the unit to service.
C. Support the CEM over a suitable container with the exhaust in-
let downwards. Leave the CEM to drain for 8 hours. Result The volume of drained oil is less than 0.4 L
(0.42 qt).
D. Check the quantity of drained oil in the container.
Proceed to Test Step 7.

7. Recover the Aftertreatment System CEM Result: The “Aftertreatment Recovery Procedure” com-
pletes with a soot load of less than 80% and no smoke from
A. Clean any remaining oil from the piping and the CEM inlet with the exhaust.
a clean cloth.
Return the unit to service.
B. Install the Clean Emissions Module (CEM). Refer to Disassem-
bly and Assembly, “Clean Emissions Module - Remove and Result The “Aftertreatment Recovery Procedure” com-
Install”. pletes with a soot load of more than 80% or smoke from the
exhaust.
C. Run the engine at high idle with no load for a minimum of 20
minutes. Contact the Dealer Solutions Network (DSN).

D. Use the electronic service tool to perform the “Aftertreatment

Recovery Procedure” . While the procedure is progressing, check
for smoke from the exhaust. Some smoke will be evident during
the procedure. The smoke must dissipate before the procedure is
completed.

i08039941 Certain operating conditions may cause the exhaust

temperature to increase to a level that may damage
Exhaust Temperature Is High engine components. If a high exhaust temperature
occurs, the ECM derates the engine to reduce the
exhaust temperature. The engine is derated only to a
level that allows the exhaust temperature to return to
The Electronic Control Module (ECM) monitors the an acceptable level.
temperature sensor in the outlet from the low-
pressure turbocharger. Probable Causes
• Inlet system leak
• Engine operating conditions

• Failed engine intake throttle valve

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Symptom Troubleshooting

• High altitude
• Obstructed Air-to-Air Aftercooler (ATAAC)

Illustration 22 g03844797
Example of an electronic service tool screenshot of the histogram. This histogram is populated when the engine
system has calculated a condition in which high exhaust temperatures are present. A diagnostic code will not be
logged when the system calculates a high exhaust temperature condition. The engine will be derated to protect the
engine system. This situation is normal under most circumstances and no additional troubleshooting is necessary.

Note: Information from this histogram is to be used

with active and logged diagnostic trouble codes. This
histogram is for information only.
Complete the procedure in the order in which the
steps are listed.

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 M0095947-10 143
Symptom Troubleshooting

Table 78
Troubleshooting Test Steps Values Results

1. Check for Inlet System Leakage Boost leaks Result: Leakage was found.

A. Apply a light load to the engine and check for leakage from the Repair: Repair the leaks. Return the unit to service.
inlet system downstream of the turbocharger.
Result: Leakage was not found.

Proceed to Test Step 2.

2. Check the Engine Operating Conditions Normal Result: The code was logged during a heavy load.
operation
A. Use the electronic service tool to check the histograms. Use Repair: Reduce the load on the engine. Return the unit to
the histograms to determine if the high exhaust temperature was service.
due to normal operation.
If possible, interview the operator. Determine if the engine is Result: The code was not logged during a heavy load.
being operated under heavy load. Ensure that the engine is being
operated at an acceptable engine speed. Proceed to Test Step 3.

If derates are suspected, reset the histogram and return the unit
to service. If the histogram repopulates without fault codes, the
derating of the engine was under normal engine operation.

3. Check the Engine Intake Throttle Valve Failed engine Result: The engine intake throttle valve has failed.
intake throttle
A. Check the engine intake throttle valve for correct operation. valve Repair: Repair or replace the valve.
Use the electronic service tool to perform the “Air System Motor
Valves Verification Test” . If the “Air System Motor Valves Verifica- Refer to Disassembly and Assembly, Throttle Valve (intake
tion Test” indicates a fault, refer to Troubleshooting, “Motorized Air) - Remove and Install.
Valve - Test” for the correct troubleshooting procedure.
If a new valve is fitted, use the electronic service tool to run
the “Engine Throttle Valve Replacement Reset” and then
use the electronic service tool to run the “Air System Motor
Valves Verification Test” .

If the valve is repaired, use the electronic service tool to per-

form the “Air System Motor Valves Verification Test” and
verify that the repair eliminates the fault.

Result: The engine intake throttle valve has not failed.

Proceed to Test Step 4.

(continued)

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(Table 78, contd)

Troubleshooting Test Steps Values Results

4. Check the Engine Operating Altitude High opera- Result: The engine was operating at high altitudes.
tional altitudes
A. Check the engine operating altitude. The high exhaust temperature was due to high altitudes.
Return the unit to service.
Note: High altitudes can cause high exhaust temperatures, con-
sider the operational altitude when troubleshooting a high exhaust Result: The engine was not operating at high altitudes.
temperature. High exhaust temperatures are associated with high
operational altitudes. Proceed to Test Step 5.

When operating below 5500ft and the ambient temperature is be-

low 30° C (85° F), altitude should not cause a high exhaust tem-
perature derate.

5. Check for an Obstructed Air-to-Air Aftercooler (ATAAC) Obstructed Result: The engine ATAAC was obstructed.
aftercooler
A. The intake manifold air temperature can increase if the flow Repair: Clear any obstructions. Return the unit to service.
through the ATAAC is obstructed. Check the ATAAC for obstruc-
tions or debris. Ensure that the flow of air or coolant through the If the procedure did not correct the issue, contact the Dealer
ATAAC is adequate. Solutions Network (DSN).

i08056591

Fuel Consumption Is
Excessive

Probable Causes
• Diagnostic codes
• Misreading of fuel level

• Fuel leakage
• Fuel quality

• Quality of oil
• Coolant temperature

• Prolonged operation at idle speed

• Air intake and exhaust system
• Cooling fan

• Reduced pressure of intake air

• Excessive valve lash

• Failure of the primary speed/timing sensor

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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 M0095947-10 145
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Table 79
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Diagnostic Result: A diagnostic code is present.

codes
Note: Certain diagnostic codes and/or event codes may cause Repair: Troubleshoot the code and then verify that the fuel
high fuel consumption. consumption is normal.

Result: A diagnostic code is not present.

A. Use the electronic service tool to check for active or logged Proceed to Test Step 2.
codes.

2. Misreading of Fuel Level Fuel level Result: Fuel consumption is normal for the operating
conditions.
Note: Misreading of the fuel gauge can give a false indication of
fuel consumption. Return the unit to service.

A. Monitor the fuel consumption over a period of 50 engine Result: Fuel consumption is high for the operating
hours. conditions.

Proceed to Test Step 3.

3. Fuel Leakage Fuel leaks Result: Evidence of a fuel leak is found.

A. Check the engine for signs of fuel leakage. Repair: Repair or replace the component that is leaking
fuel.

Result: No evidence of a fuel leak is found.

Proceed to Test Step 4.

4. Fuel Quality Fuel quality Result: The fuel quality does not meet specifications.

Note: The grade of the fuel affects the rate of fuel consumption. Repair: Drain the fuel system and replace the fuel filters.
Refer to the engines Operation and Maintenance Manual for ad- Refer to the Operation and Maintenance Manual, “Fuel Sys-
ditional information. tem Primary Filter (Water Separator) Element - Replace”
and Operation and Maintenance Manual, “Fuel System Fil-
Cold weather adversely affects the characteristics of the fuel. ter - Replace”.
Refer to the Operation and Maintenance Manual for information
on improving the characteristics of the fuel during cold-weather Fill the fuel system with fuel that meets the standard in the
operation. Operation and Maintenance Manual, “Fluid
Recommendations”.
A. Check the fuel quality. Refer to Systems Operation, Testing
and Adjusting, “Fuel Quality - Test”. Prime the fuel system. Refer to the Operation and Mainte-
nance Manual, “Fuel System - Prime”.
B. Refer to Operation and Maintenance Manual for information
on the proper characteristics of the fuel for the engine. Result: The fuel quality meets specifications.

Proceed to Test Step 5.

(continued)

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(Table 79, contd)

Troubleshooting Test Steps Values Results

5. Quality of Oil Engine oil Result: The engine oil does not meet the required
quality specification.
Note: The nominal viscosity of the lubricating oil that is used in
the engine will affect the rate of fuel consumption. The viscosity Repair: Drain and fill the oil system with oil of an acceptable
of lubricating oil is defined by the SAE grade of the lubricating quality. Refer to the applicable sections in the Operation
oil. The grade of the lubricating oil must be correct for the ambi- and Maintenance Manual.
ent conditions. Lubricating oil for high ambient temperatures will
affect fuel consumption in cold ambient temperatures. Result: The engine oil meets the required specification.

A. Check that the engine oil meets the required specification. Proceed to Test Step 6.
Refer to “Engine Oil” in the Operation and Maintenance Manual,
“Refill Capacities”.

6. Coolant Temperature Coolant Result: The water temperature regulator is not operating
temperature correctly.
Note: The operating temperature of the engine will affect the
rate of fuel consumption. Operation of the engine below the cor- Repair: Replace the water temperature regulator. Verify
rect temperature will increase fuel consumption. Failure of the that the repair corrected the fault.
water temperature regulator can prevent the engine from oper-
ating at the correct temperature. Result: The water temperature regulator is operating
correctly.
A. Check that the water temperature regulator is operating cor-
rectly. Refer to Systems Operation, Testing and Adjusting, Proceed to Test Step 7.
“Water Temperature Regulator - Test”.

7. Prolonged Operation at Idle Speed Extended idle Result: The engine is operating at idle speed for extended
operation periods.
Note: Prolonged operation of the engine at idle speed increases
fuel consumption. When possible, stop the engine to conserve fuel.

A. Check for extended periods of engine operation at idle Result: The engine is not operating at idle speed for ex-
speed. tended periods.

Proceed to Test Step 8.

8. Air Intake and Exhaust System Air and Exhaust Result: The air filter is restricted.
System
A. Check the air filter restriction indicator, if equipped. restrictions Repair: Replace the air filter.

B. Check the air intake and exhaust systems for the following Result: There are system restrictions.
defects:
Repair: Refer to Systems Operation, Testing and Adjusting,
· Blockages “Air Inlet and Exhaust System” for additional information on
· Restrictions the air inlet and exhaust systems.
· Damage to lines or hoses
Result: The air intake and exhaust system is OK.

Proceed to Test Step 9.

(continued)

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Symptom Troubleshooting

(Table 79, contd)

Troubleshooting Test Steps Values Results

9. Cooling Fan Cooling fan Result: The cooling fan is operating excessively.

Note: Excessive operation of the cooling fan or damage to the Repair: Repair or replace the faulty cooling fan
cooling fan will increase fuel consumption. components.

A. Check the operation and condition of the cooling fan. Result: The cooling fan is damaged excessively.

Repair: Repair or replace the faulty cooling fan

components.

Result: The cooling fan is not operating excessively and is

not damaged.

Proceed to Test Step 10.

10. Reduced Pressure of Intake Air Intake air Result: There is a leak in the intake air system.

Note: If the air pressure is lower than normal, the same power Repair: Repair the leak or replace the component that is
can only be achieved by the following: causing the leak.

· Higher engine speed Result: The turbocharger wastegate is not operating

· Injection of more fuel correctly.

Either of these conditions will increase the fuel consumption. Repair: Replace the turbocharger.

A. Check all pipes from the outlets of the turbocharger compres- If the turbocharger is replaced, use the electronic service
sor to the inlet manifold for leaks. tool to perform the “Turbocharger Wastegate Actuator Re-
placement Reset” .
B. Check for the correct operation of the wastegate in the Use the electronic service tool to perform the “Air System
turbocharger. Motor Valve Verification Test”

Result: The air intake system and the wastegate are OK.

Proceed to Test Step 11.

11. Excessive Valve Lash Valve lash Result: The valve lash is incorrect.

A. Check for excessive valve lash. Repair: Check the valve lash. Refer to Systems Operation,
Testing and Adjusting, “Engine Valve Lash - Inspect” for the
correct procedure.

Result: The valve lash is correct.

Proceed to Test Step 12.

12. Failure of the Primary Speed/Timing Sensor Primary Speed/ Result: The primary speed/timing sensor is not operating
Timing Sensor correctly.
A. Crank the engine and observe the engine speed on the elec-
tronic service tool status screen. Repair: Test the primary speed/timing sensor. Refer to
Troubleshooting, “Speed/Timing - Test”.
Upon initial cranking, the status for engine speed may indicate
that the engine speed signal is abnormal. This message will be Result: The primary speed/timing sensor is operating
replaced with an engine speed once the ECM is able to calcu- correctly.
late a speed from the signal.
Contact the Dealer Solutions Network (DSN).

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i07710968

Fuel Contains Water

This procedure covers the following diagnostic code:

Table 80

Diagnostic Trouble Code for Water in Fuel

J1939 Code Code Description Comments

Water has been detected in the fuel that is contained in the fuel/water separator
Water In Fuel Indicator : High - least se- bowl. The water has been present for at least 5 seconds.
97-15
vere (1)
The warning lamp will come on.

Water has been detected in the fuel that is contained in the fuel/water separator
bowl. The water has been present for at least 60 minutes.
Water In Fuel Indicator : High - moderate
97-16
severity (2) The warning lamp will come on.

The engine will be derated at 10% per second up to a maximum of 100%.

Note: Visual identification of water in the bowl may

be impossible. Water may turn dark yellow in the fuel
system. The similarity in color would prevent the
ability to differentiate the water from the fuel.

Recommended Actions
Note: Complete the procedure in the order in which
the steps are listed.

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Symptom Troubleshooting

Table 81
Troubleshooting Test Steps Values Results

1. Drain the Fuel/Water Separator Bowl Fuel/water Result: The “Water-In-Fuel” warning disappears within 1
separator minute.
A. Turn the ignition key to the OFF position.
Proceed to Test Step 2.
B. Drain the fuel/water separator bowl. Refer to the Operation and
Maintenance Manual, “Fuel System Primary Filter/Water Separa- Result: The “Water-In-Fuel” warning remains on.
tor - Drain”.
Proceed to Test Step 3.
C. If necessary, prime the fuel system. Refer to the Operation and
Maintenance Manual, “Fuel System - Prime”.

D. Turn the ignition key to the ON position. Do not start the engine.
Wait for 1 minute.

2. Confirm that there is no Water in the Fuel Water in fuel Result: The “Water-In-Fuel” warning does not reappear
within the 5 minutes.
A. Run the engine for 5 minutes.
Return the unit to service.

Result: The “Water-In-Fuel” warning reappears within the 5

minutes.

Repair: The fuel supply is contaminated with water. Drain

the fuel tank and then fill the fuel tank with clean fuel.

Repeat the procedure from Test Step 1.

If the fault is still present, contact the Dealer Solutions Net-

work (DSN).

3. Water-In-Fuel Switch Water in fuel Result: The Water-In-Fuel switch circuit required a repair.
switch
A. Check the operation of the Water-In-Fuel switch. Refer to Trou- Repeat the procedure from Test Step 1.
bleshooting, “Water In Fuel - Test”.
Result The Water-In-Fuel switch is OK.

Repair: The fuel supply is contaminated with water. Drain

the fuel tank and then fill the fuel tank with clean fuel.

Repeat the procedure from Test Step 1.

If the fault is still present, contact the Dealer Solutions Net-

work (DSN).

i08368448

Fuel Rail Pressure Problem

Use this procedure to troubleshoot abnormal fuel rail

pressure or use this procedure if any of the following
diagnostic trouble codes are active. Refer to
Troubleshooting, “Diagnostic Trouble Codes” for
information about the codes.

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Table 82
Diagnostic Trouble Codes for Fuel Rail Pressure Problem

J1939 Code Code Description Comments

157-16 Engine Injector Metering Rail #1 Pressure: High - moderate No other 157-XX codes are active.
severity (2) 3509-XX codes are not active.
3510-XX codes are not active.
No codes for the high-pressure fuel pump or the injectors
are active.
The fuel rail pressure is above an acceptable level.
The code is logged.
Engine power is derated.

157-18 Engine Injector Metering Rail #1 Pressure: Low - moderate No other 157-XX codes are active.
severity (2) 3509-XX codes are not active.
3510-XX codes are not active.
No codes for the high-pressure fuel pump or the injectors
are active.
The fuel rail pressure is below an acceptable level.
The code is logged.
Engine power is derated.

5571-0 High Pressure Common Rail Fuel Pressure Relief Valve : 3509-XX codes are not active.
Active 3510-XX codes are not active.
The pressure limiting valve in the fuel rail is open. This
code is a calculated parameter.
The code is logged.

Probable Causes
• Diagnostic codes

• Electrical connectors
• Fuel filters

• Fuel rail pressure sensor

• High-pressure fuel pump calibration
• Fuel system

Recommended Actions

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

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 M0095947-10 151
Symptom Troubleshooting

Table 83
Troubleshooting Test Steps Values Results

1. Download Information Using the Electronic Service Tool Downloaded Result: The information was successfully saved.
information
A. Use the electronic service tool to download the “Product Status Proceed to Test Step 2.
Report” (PSR) with histograms before performing any trouble-
shooting or clearing any diagnostic codes. Result: The electronic service tool information was not
successfully saved.
Note: The downloaded information will be required by the Dealer
Solutions Network (DSN) if troubleshooting assistance is required. Contact the Dealer Solutions Network (DSN) for
guidance.

2. Create an Electronic Service Tool Snapshot Snapshot saved Result: The electronic service tool snapshot was suc-
cessfully saved.
A. Select “Snapshot Viewer” on the electronic service tool, using
menus: Information -> Snapshot -> Viewer Proceed to Test Step 3.

B. Select the event code and then click “View Graph” . Result: The electronic service tool snapshot was not
successfully saved.
C. Select the following parameter and then click OK.
Contact the DSN for guidance.
· Engine Speed

D. Select Save to "File to save" a Snapshot File (*.xml). This file

will contain all the data in the snapshot and not only the data
shown on the graph.
Note: The downloaded information will be required by the DSN if
troubleshooting assistance is required.

3. Diagnostic Codes Diagnostic codes Result: One of the codes in Table 82 is present.

A. Connect the electronic service tool to the diagnostic connector. Proceed to Test Step 4.
Refer to Troubleshooting, “Electronic Service Tools”, if necessary.
Result: A code other than the codes in Table 82 is
B. Determine if a diagnostic is active or recently logged. present.

Repair: Troubleshoot the code. Refer to the applicable

troubleshooting procedure.

4. Fuel Rail Pressure Sensor Pressure sensor Result: The “Fuel Rail Pressure (absolute)” is more
than 5,000 kPa (725 psi).
A. Make sure that the engine has been shut down for at least 10
minutes. Use the electronic service tool to check the status of the Repair: Test the fuel rail pressure sensor. Refer to Trou-
“Fuel Rail Pressure” . bleshooting, “Sensor Signal (analog, Active) - Test”.

Use the electronic service tool to perform the "Fuel Rail

Pressure Test". If the test fails, replace the fuel rail. Re-
fer to Disassembly and Assembly, “Fuel Manifold (Rail)
- Remove and Install”.

Confirm that the fault has been eliminated.

Result: The “Fuel Rail Pressure (absolute)” is less than

5,000 kPa (725 psi).

Proceed to Test Step 5.

(continued)

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(Table 83, contd)

Troubleshooting Test Steps Values Results

5. Electrical Connectors Connectors Result: There are suspect connectors.

A. Check for the correct installation of the ECM J1/P1 and the J2/ Repair: Use the electronic service tool to perform the
P2 connectors. Check for correct installation of the connector on “Wiggle Test” .
the fuel rail pressure sensor.
Check for correct installation of the connector for the flow control Repair or replace connectors that are suspect.
valve on the high-pressure fuel pump.
Result: There are no suspect connectors.

Proceed to Test Step 6.

6. High-Pressure Fuel Pump Calibration Fuel system Result: Fuel rail pressure is normal after performing the
“High Pressure Fuel Pump Calibration” .
A. Use the electronic service tool to perform the “High Pressure
Fuel Pump Calibration” . Return the unit to service.

Result: Fuel rail pressure is still high after performing

the “High Pressure Fuel Pump Calibration” .

Run the engine for a minimum of 30 minutes.

Proceed to Test Step 7.

7. Fuel System Fuel system Result: There is a leak from the high-pressure fuel
system.
A. Visually check the fuel tank for fuel.
Repair: Rectify any fuel leaks.
Note: The fuel gauge may be faulty.
Result: The fuel contains solidified wax.
B. Check the primary filter/water separator for water in the fuel or
debris. Repair: Replace the fuel with fuel of the correct specifi-
cation for the ambient conditions.
C. If the temperature is below 0 °C (32 °F), check for solidified Replace any filters and/or screens in the fuel system.
fuel (wax). Refer to Operation and Maintenance Manual for further
information.
D. Check that the EPP is operating correctly.
Result: There are fuel supply lines that are restricted or
E. Check for fuel supply lines that are restricted or not correctly not correctly installed.
installed.
Repair: Install the fuel lines correctly. Replace any dam-
F. Check for air in the fuel system and that the fuel system is aged or restricted fuel lines.
primed.
Result: The EPP is not operating correctly.
G. Use the electronic service tool to perform the “Fuel Rail Pres-
sure Relief Valve Test” . Repair: Investigate the fault with the EPP. Refer to
Troubleshooting, “Fuel Transfer Pump - Test”.
H. Inspect the high-pressure fuel system for leaks.
Result: There is air in the fuel system.
I. Replace the in-line fuel filter that is installed upstream of the
Electric Priming Pump (EPP). Repair: Prime the fuel system. Refer to Systems Opera-
tion, Testing, and Adjusting, “Fuel System - Prime”.
J. Replace any filters and/or screens in the fuel system. Refer to
Operation and Maintenance Manual for further information. Result: The diesel fuel is contaminated.

K. Check the diesel fuel for contamination. Refer to Systems Op- Repair: Drain the fuel tank and the fuel system.
eration, Testing, and Adjusting, “Fuel Quality - Test”.

(continued)

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(Table 83, contd)

Troubleshooting Test Steps Values Results
Note: This test will identify excessive leakage through the Pres- Replace any filters and/or screens in the fuel system.
sure Limiting Valve (PLV) in the fuel rail. Refer to Operation and Maintenance Manual for further
information.

Fill and prime the fuel system with fuel of the correct
specification. Refer to Systems Operation, Testing, and
Adjusting, “Fuel System - Prime”.

Result: The low-pressure fuel system is OK.

If the fault is still present, contact the DSN and provide

the following information from Test Step 1 and Test Step
2:
• PSR and Histograms
• Snapshot data

i07581514

Fuel Temperature Is High

If either of the following diagnostic trouble codes are

active, perform the procedure that follows:
Table 84
Diagnostic Trouble Codes for Fuel Temperature Is High

J1939 Code Code Description Comments

174-16 Engine Fuel Temperature 1 : High - moderate severity (2) The temperature of the low-pressure fuel in the high-pres-
sure fuel pump is high.

The ECM has been powered for at least 2 seconds.

The engine has been operating for at least 185 seconds.

There are no other faults in the electrical system.

The warning lamp will come on.

The engine may be derated by up to 100%.

The warning lamp will go off when the temperature drops

below the trip point for 15 seconds.

Probable causes
• Incorrect position of fuel shut-off valves
• Fuel level in tank

• Return fuel cooler

• Return fuel lines

• Location of the fuel tank

Note: The procedures have been listed in order of
probability. Complete the procedure in the order in
which the steps are listed.

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Symptom Troubleshooting

Table 85
Troubleshooting Test Steps Values Results

1. Download Information Using the Electronic Service Tool Downloaded Result: The information was successfully saved.
information
A. Use the electronic service tool to download the “Product Sta- Proceed to Test Step 2.
tus Report” (PSR) with histograms before performing any trouble-
shooting or clearing any diagnostic codes. Result: The electronic service tool information was not
successfully saved.
Note: The downloaded information will be required by the Dealer
Solutions Network (DSN) if troubleshooting assistance is Contact the Dealer Solutions Network (DSN) for
required. guidance.

2. Create an Electronic Service Tool Snapshot Snapshot saved Result: The electronic service tool snapshot was suc-
cessfully saved.
A. Select “Snapshot Viewer” on the electronic service tool, using
menus: Information -> Snapshot -> Viewer Proceed to Test Step 3.

B. Select the event code and then click “View Graph” . Result: The electronic service tool snapshot was not suc-
cessfully saved.
C. Select the following parameter and then click OK.
Contact the DSN for guidance.
· Engine Speed

D. Select Save to "File to save" a Snapshot File (*.xml). This file

will contain all the data in the snapshot and not only the data
shown on the graph.
Note: The downloaded information will be required by the DSN if
troubleshooting assistance is required.

3. Check for Diagnostic Codes Active or Logged Diagnostic Diagnostic Active Result: A diagnostic code is active or logged other than a
codes. or Logged codes 174-16 code.

A. Establish communication between the electronic service tool Repair: Troubleshoot the active or logged code.
and the Electronic Control Module (ECM). Refer to Troubleshoot-
ing, “Electronic Service Tools”, if necessary. Result: A 174-16 diagnostic code is active or logged.

B. Use the electronic service tool to check for active or logged Proceed to Test Step 4.
codes.

4. Fuel Shut-off Valves Fuel valves Result: A fuel shut-off valve is not fully open.

A. Check the position of any fuel shut-off valves in the feed lines Repair: Move all shut-off valves to the fully open position.
between the fuel tank and the engine.
Result: All shut-off valves are in the fully open position.
B. Check the position of any fuel shut-off valves in the return lines
between the engine and the fuel tank. Proceed to Test Step 5.

5. Fuel Level in Tank Fuel level Result: The fuel level in the tank is low.

Note: If the level in the fuel tank is low, the hot return fuel can Repair: Replenish the fuel tank at the earliest opportunity.
raise the temperature in the fuel tank.
Result: The fuel level in the tank is OK.
A. Check the fuel level in the tank.
Proceed to Test Step 6.

(continued)

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(Table 85, contd)

6. Return Fuel Cooler Return fuel Result: The fins on the return fuel cooler are blocked with
cooler dirt or debris.
A. Check that the fins on the return fuel cooler are not blocked
with dirt or debris. Make sure that the fins are not bent or Repair: Clean the return fuel cooler.
missing.
Result: The fins on the return fuel cooler are bent or
missing.

Repair: Install a replacement return fuel cooler.

Result: The return fuel cooler is OK.

Proceed to Test Step 7.

7. Return Fuel Lines Return fuel lines Result: A return fuel line is blocked or restricted.

A. Check the return fuel lines for blockages or restrictions. Repair: Clear the fuel line or replace the line.

Result: The return fuel lines are OK.

Proceed to Test Step 8.

8. Location of the Fuel Tank Fuel tank Result: The fuel tank is close to a heat source.
location
A. Make sure that the fuel tank is not close to a heat source. Repair: Shield the fuel tank from the heat source.

Result: The fuel tank is not close to a heat source.

If the fault is still present, contact the DSN and provide the
following information from Test Step 1 and Test Step 2:
• PSR and Histograms
• Snapshot data

i07928862

Inlet Air Is Restricted

Use this procedure to troubleshoot a high differential

pressure for the air inlet system. Use this procedure if
one of the following event codes are active. For
information on the engine monitoring system, refer to
Troubleshooting, “Engine Monitoring System”.
Table 86

Diagnostic Trouble Codes for Inlet Air Is Restricted

J1939 Code Code Description Comments

The air filter differential pressure is above the trip point pressure for the de-
Engine Air Filter 1 Differential Pressure : High -
107-15 lay time.
least severe (1)
The code is logged.

The air filter differential pressure is above the trip point pressure for the de-
Engine Air Filter 1 Differential Pressure : High - lay time.
107-16
moderate severity (2) The code is logged.
The engine power is derated.

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Complete the procedure in the order in which the

steps are listed.
Table 87
Troubleshooting Test Steps Values Results

1. Check the Air Filter Element Plugged air filter Result: The air filter is clogged.

A. Check the air intake system for plugged air filters or for dam- Repair: Clean or replace the air filter. Verify that the
aged air filters. If the engine is equipped with an air intake pre- problem is resolved.
cleaner, verify the proper operation of the air intake precleaner.
Result: The air filter is not clogged.

Proceed to Test Step 2.

2. Check the Air Inlet Piping Damaged air inlet Result: The air inlet piping is damaged or has
piping restrictions.
A. Check the air inlet piping for damage or restrictions.
Repair: Repair the piping or replace the piping. Veri-
fy that the problem is resolved.

Result: The air inlet piping does not have damage

or restrictions.

Proceed to Test Step 3.

3. Check the Enclosure Ventilation Enclosure ventilation Result: The engine does not have sufficient
ventilation.
A. Check that the engine has been installed in an enclosure that is
sufficiently ventilated. Repair: Repair the ventilation for the enclosure. Ver-
ify that the fault is resolved.

Result: The engine has sufficient ventilation.

Contact the Dealer Solutions Network (DSN).

i08056604

Intake Manifold Air Pressure Is

High

The Electronic Control Module (ECM) monitors the

intake manifold air pressure. The following event is
associated with high intake manifold air pressure:
Table 88
Diagnostic Trouble Code for Intake Manifold Air Pressure Is High

J1939 Code Code Description Comments

This pressure is a variable value that is calculated by the ECM.
Engine Intake Manifold #1 Pressure : High - moderate severity
102-16 The resulting value depends on the operating conditions of the
(2)
engine.

Probable Causes
• Turbocharger electronic wastegate regulator

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Symptom Troubleshooting

Recommended Actions

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Table 89
Troubleshooting Test Steps Values Results

1. Download Information Using the Electronic Service Downloaded Result: The information was successfully saved.
Tool information
Proceed to Test Step 2.
A. Use the electronic service tool to download the “Product
Status Report” (PSR) with histograms before performing any Result: The electronic service tool information was not suc-
troubleshooting or clearing any diagnostic codes. cessfully saved.

Note: The downloaded information will be required by the Contact the Dealer Solutions Network (DSN) for guidance.
Dealer Solutions Network (DSN) if troubleshooting assis-
tance is required.

2. Create an Electronic Service Tool Snapshot Snapshot saved Result: The electronic service tool snapshot was successfully
saved.
A. Select “Snapshot Viewer” on the electronic service tool,
using menus: Information -> Snapshot -> Viewer Proceed to Test Step 3.

B. Select the event code and then click “View Graph” . Result: The electronic service tool snapshot was not success-
fully saved.
C. Select the following parameter and then click OK.
Contact the DSN for guidance.
· Engine Speed

D. Select Save to "File to save" a Snapshot File (*.xml). This

file will contain all the data in the snapshot and not only the
data shown on the graph.
Note: The downloaded information will be required by the
DSN if troubleshooting assistance is required.

3. Turbocharger Electronic Wastegate Regulator Turbocharger Result: Diagnostic codes became active during the “Air Sys-
wastegate tem Motor Valves Verification Test”
A. Use the electronic service tool to perform the “Air System
Motor Valves Verification Test” to check that the turbocharger Repair: Troubleshoot the diagnostic codes. Refer to Trouble-
wastegate is operating correctly. shooting, Diagnostic Trouble Codes.

B. Inspect the turbocharger. Refer to Systems Operation, If the wastegate is not operating correctly, disconnect the link-
Testing and Adjusting, “Turbocharger - Inspect”. age from the actuator by removing the circlips. Check the
crank on the turbine housing for free movement. If the crank
moves freely, replace the wastegate actuator.
If the turbocharger wastegate is replaced, use the electronic
service tool to perform the “Turbocharger Wastegate Actuator
Replacement Reset” .
Use the electronic service tool to perform the “Air System Mo-
tor Valve Verification Test” to verify that the repair eliminates
the fault.
If the crank does not move freely, replace the turbocharger as-
sembly. Refer to Disassembly and Assembly, Turbocharger -
Remove and Disassembly and Assembly, Turbocharger -
Install.
If the turbocharger is replaced, use the electronic service tool
to perform the “Turbocharger Wastegate Actuator Replace-
ment Reset” .
Use the electronic service tool to perform the “Air System Mo-
tor Valve Verification Test” to verify that the repair eliminates
the fault.

Result: There is a suspected fault in the wastegate or the

wastegate actuator.

(continued)

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(Table 89, contd)

Troubleshooting Test Steps Values Results

Repair: Replace the turbocharger. Refer to Disassembly and

Assembly, “Turbocharger - Remove” and Disassembly and
Assembly, “Turbocharger - Install”.

If the turbocharger is replaced, use the electronic service tool

to perform the “Turbocharger Wastegate Actuator Replace-
ment Reset” .
Use the electronic service tool to perform the “Air System Mo-
tor Valve Verification Test”

Result: The wastegate and the wastegate actuator operate

correctly.

If the fault is still present, contact the DSN and provide the fol-
lowing information from Test Step 1 and Test Step 2:
• PSR and Histograms
• Snapshot data

i08072922

Intake Manifold Air Pressure Is

Low

The Electronic Control Module (ECM) monitors the

intake manifold air pressure. The following event is
associated with low intake manifold air pressure:
Table 90
Diagnostic Trouble Code for Low Intake Manifold Air Pressure

J1939 Code Description Notes

Code
102-18 Engine Intake Manifold #1 Pressure : Low - moderate severity This pressure is a variable value that is calculated by the ECM.
The resulting value depends on the operating conditions of the
engine.

Probable Causes
• Intake air filter
• Air intake system

• Turbocharger electronic wastegate regulator or

engine intake throttle valve

• Turbocharger

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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Table 91
Troubleshooting Test Steps Values Results

1. Download Information Using the Electronic Service Downloaded Result: The information was successfully saved.
Tool information
Proceed to Test Step 2.
A. Use the electronic service tool to download the “Product
Status Report” (PSR) with histograms before performing any Result: The electronic service tool information was not suc-
troubleshooting or clearing any diagnostic codes. cessfully saved.

Note: The downloaded information will be required by the Contact the Dealer Solutions Network (DSN) for guidance.
Dealer Solutions Network (DSN) if troubleshooting assistance
is required.

2. Create an Electronic Service Tool Snapshot Snapshot saved Result: The electronic service tool snapshot was successfully
saved.
A. Select “Snapshot Viewer” on the electronic service tool,
using menus: Information -> Snapshot -> Viewer Proceed to Test Step 3.

B. Select the event code and then click “View Graph” . Result: The electronic service tool snapshot was not success-
fully saved.
C. Select the following parameter and then click OK.
Contact the DSN for guidance.
· Engine Speed

D. Select Save to "File to save" a Snapshot File (*.xml). This

file will contain all the data in the snapshot and not only the
data shown on the graph.
Note: The downloaded information will be required by the
DSN if troubleshooting assistance is required.

3. Intake Air Filter Air filter Result: The air filter is blocked.

A. Check the air filter restriction indicator, if equipped. Repair: Replace the air filter element. Refer to the Operation
and Maintenance Manual, “Engine Air Cleaner Element -
B. Ensure that the air filter is clean and serviceable. Replace”.

Result: The air filter is OK.

Proceed to Test Step 4.

4. Air Intake System Air intake Result: The air intake system is blocked, restricted, damaged,
or loose.
A. Check the air intake system for the following defects:
Repair: Make all necessary repairs to the air intake system.
· Blockages
· Restrictions Result: The air intake system is OK.
· Damage to the air intake ducts and hoses
· Loose connections and air leaks Proceed to Test Step 5.

(continued)

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Symptom Troubleshooting

(Table 91, contd)

Troubleshooting Test Steps Values Results

5. Turbocharger Electronic Wastegate Regulator or En- Turbocharger Result: Diagnostic codes became active during the “Air Sys-
gine Intake Throttle Valve wastegate tem Motor Valves Verification Test”

A. Use the electronic service tool to perform the “Air System Repair: Troubleshoot the diagnostic codes. Refer to Trouble-
Motor Valves Verification Test” to check that the turbocharger shooting, Diagnostic Trouble Codes.
wastegate is operating correctly.
If the wastegate is not operating correctly, disconnect the link-
B. Inspect the turbocharger. Refer to Systems Operation, age from the actuator by removing the circlips. Check the
Testing and Adjusting, “Turbocharger - Inspect”. crank on the turbine housing for free movement. If the crank
moves freely, replace the wastegate actuator.
Use the electronic service tool to perform the “Air System Mo-
tor Valve Verification Test” to verify that the repair eliminates
the fault.
If the crank does not move freely, replace the turbocharger as-
sembly. Refer to Disassembly and Assembly, Turbocharger -
Remove and Disassembly and Assembly, Turbocharger -
Install.

If the turbocharger is replaced, use the electronic service tool

to perform the “Turbocharger Wastegate Actuator Replace-
ment Reset” .
Use the electronic service tool to perform the “Air System Mo-
tor Valve Verification Test” to verify that the repair eliminates
the fault.
Result: There is a suspected fault in the wastegate or the
wastegate actuator.

Repair: Replace the turbocharger. Refer to Disassembly and

Assembly, “Turbocharger - Remove” and Disassembly and
Assembly, “Turbocharger - Install”.

If the turbocharger is replaced, use the electronic service tool

to perform the “Turbocharger Wastegate Actuator Replace-
ment Reset” .
Use the electronic service tool to perform the “Air System Mo-
tor Valve Verification Test” to verify that the repair eliminates
the fault.

Result: The wastegate and the wastegate actuator operate

correctly.

Proceed to Test Step 6.

6. Turbocharger Turbocharger Result: There is a fault in the turbocharger.

A. Check that the compressor housing for the turbocharger is Repair: Replace the turbocharger. Refer to Disassembly and
free of dirt and debris. Assembly, “Turbocharger - Remove” and Disassembly and
Assembly, “Turbocharger - Install”.
B. Check that the turbine housing for the turbocharger is free
of dirt and debris. If the turbocharger is replaced, use the electronic service tool
to perform the “Turbocharger Wastegate Actuator Replace-
C. Check that the turbine blades rotate freely in the ment Reset” .
turbocharger. Use the electronic service tool to perform the “Air System Mo-
tor Valve Verification Test” to verify that the repair eliminates
the fault.

Result: The turbocharger is OK.

Contact the Dealer Solutions Network (DSN).

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i08040999

Intake Manifold Air

Temperature Is High

The Electronic Control Module (ECM) monitors the

intake manifold air for excessive temperature. The
following event codes are associated with high intake
manifold air temperature:
Table 92
Diagnostic Trouble Codes for High Intake Manifold Air Temperature

J1939 Code Description Comments

Code
The engine has been running for 3 minutes.
No other 105 codes are active.
168 codes are not active.
Code 412-16 is not active.
105-15 Engine Intake Manifold #1 Temperature : High - least severe (1)
The intake manifold air temperature exceeds the value that is
programmed into the ECM for 8 seconds. The code is logged.
This code will be reset when the temperature is less than 122° C
(252° F) for 4 seconds.

The engine has been running for 3 minutes.

No other 105 codes are active.
168 codes are not active.
Code 412-16 is not active.
Engine Intake Manifold #1 Temperature : High - Moderate Se-
105-16 The intake manifold air temperature exceeds the value that is
verity (2)
programmed into the ECM for 8 seconds. The engine will be de-
rated. The code is logged.
This code will be reset when the temperature is less than 124° C
(255° F) for 20 seconds.

The engine has been running for 3 minutes.

No other 105 codes are active.
168 codes are not active.
Code 412-16 is not active.
105-0 Engine Intake Manifold #1 Temperature : High - most severe (3) The intake manifold air temperature exceeds the value that is
programmed into the ECM for 8 seconds. The engine will be
shut down. The code is logged.
This code will be reset when the temperature is less than 124° C
(255° F) for 20 seconds.

Probable Causes Recommended Actions

• Coolant level Note: The procedures have been listed in order of
probability. Complete the procedures in order.
• Air-to-air aftercooler (ATAAC)

• Cooling fan
• Air inlet and exhaust system

• NRS valve and engine intake throttle valve

• Ambient temperature

• Altitude
• Running condition

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Symptom Troubleshooting

Table 93
Troubleshooting Test Steps Values Results

1. Coolant Level Coolant Result: The coolant level is low.

A. Check that the coolant is filled to the correct level. Repair: Fill the coolant system to the correct level. Refer to
the Operation and Maintenance Manual, “Coolant Level -
Note: If the coolant level is too low, air will get into the cooling Check”.
system. Air in the cooling system will cause a reduction in
coolant flow. Result: The coolant level is OK.

Proceed to Test Step 2.

2. Air-to-Air Aftercooler (ATAAC) ATAAC Result: The ATAAC has excessive debris or is damaged.

A. Check the ATAAC for debris or damage. Repair: Clear the debris from the ATAAC or replace the
ATAAC.
Note: Debris between the fins of the ATAAC core restricts air
flow through the core. Result: The ATAAC is OK.

Proceed to Test Step 3.

3. Cooling Fan Cooling fan Result: The cooling fan is not operating correctly.

A. Check the operation of the cooling fan. Repair: Investigate the cause of the incorrect fan operation

Note: A fan that is not turning at the correct speed can result Result: The cooling fan is operating correctly.
in insufficient airflow through the aftercooler core.
Proceed to Test Step 4.

4. Air Intake and Exhaust System Air intake and Result: The air intake or exhaust system is blocked, re-
exhaust stricted, damaged, or loose.
A. Check the air intake and exhaust system for the following
defects: Repair: Make all necessary repairs to the air intake system.

· Blockages Result: The air intake and exhaust system is OK.

· Restrictions
· Damage to the air intake ducts and hoses Proceed to Test Step 5.
· Loose connections and air leaks

5. NRS Valve or Intake Throttle Valve Engine intake Result: There are active diagnostic codes that relate to the
throttle valve NRS valve or engine intake throttle valve.
A. Use the electronic service tool to perform the “Air System
Motor Valves Verification Test” . Repair: Troubleshoot the active diagnostic codes. Refer to
Check for active diagnostic codes that relate to the engine in- Troubleshooting, “Diagnostic Trouble Codes”.
take throttle valve.
Result: The NRS valve and engine intake throttle valve are
OK.

Proceed to Test Step 6.

(continued)

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(Table 93, contd)

Troubleshooting Test Steps Values Results

6. Ambient Temperature Ambient Result: The ambient air temperature is high.

Temperature
A. Check for a high ambient temperature. Repair: Operate the engine at reduced speed or reduced
power.
Note: When outside temperatures are too high, there is insuf-
ficient temperature difference between the outside air and the Result: The ambient air temperature is OK.
intake air.
Proceed to Test Step 7.

7. Altitude Altitude Result: The engine is being operated at high altitude.

A. Check for operation at high altitude. Repair: Operate the engine at reduced speed or reduced
power.
Note: The cooling capacity of the ATAAC is reduced as the
engine is operated at higher altitudes. Result: The engine is not being operated at high altitude.

Proceed to Test Step 8.

8. Running Condition Running Result: The engine is operating in the lug condition.
condition
A. Check that the engine is not operating in the lug condition. Repair: Reduce the load on the engine or, if possible, in-
crease the power rating of the engine.
Note: When the load that is applied to the engine is too large,
the engine will run in the lug condition. When the engine is Result: The engine is not operating in the lug condition.
running in the lug condition, engine rpm does not increase
with an increase of fuel. This lower engine rpm causes a re- Contact the Dealer Solutions Network (DSN).
duction in coolant flow through the system.

i07582697

NOx Conversion Is Low

This procedure covers the following diagnostic

codes.
Table 94
Diagnostic Trouble Codes for NOx Conversion Is Low

J1939 Code Code Description Comments

Aftertreatment #1 DEF Concentration : Other The DEF quality sensor is unable to determine the DEF quality percentage.
3516–11
Failure Mode
Aftertreatment #1 DEF Concentration : High - The Diesel Emissions Fluid (DEF) has a high concentration.
3516-15
least severe (1)

Aftertreatment #1 DEF Concentration : Low - The Diesel Emissions Fluid (DEF) has a low concentration.
3516-18
moderate severity (2)

Aftertreatment #1 SCR Catalyst Conversion Effi- The Engine Out and Tailpipe Out NOx Sensors are installed in the incorrect
4364-2
ciency : Erratic, Intermittent, or Incorrect locations.

Aftertreatment #1 SCR Catalyst Conversion Effi- The SCR System is not able to reduce NOx in the exhaust system.
4364-18
ciency : Low - moderate severity (2)

(continued)

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(Table 94, contd)

Diagnostic Trouble Codes for NOx Conversion Is Low

J1939 Code Code Description Comments

Aftertreatment #1 Inconsistent Configuration The NOx sensor software is not compatible with other modules on the CAN
7105-31
Detected C data link.
Follow the troubleshooting procedure to identify the root cause of the problem.

Table 95
Required Tools

Tool Part Number Part Description Qty

A T400236 Kit - Test 1

Table 96
Associated Diagnostic Trouble Codes
J1939 Code
412-15
412-16
4360-17
4360-18
4765-17
5298-17

Complete the procedure in the order in which the

steps are listed.

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Symptom Troubleshooting

Table 97
Troubleshooting Test Steps Values Results

1. Determine the Code Diagnostic trou- Result: An associated code is active or logged.
ble code
A. Establish communication between the electronic service tool Note: Troubleshoot associated codes before continuing
and the Electronic Control Module (ECM). Refer to Troubleshoot- with this procedure.
ing, “Electronic Service Tools”, if necessary.
Refer to Troubleshooting, “Diagnostic Trouble Codes” for
B. Determine the diagnostic trouble code that is active. further information.

Result: A 4364-2 code is active or logged.

Proceed to Test Step 2.

Result: A 3516–11, 3516-15 , 3516-18, or 4364-18 code

is active or logged.

Proceed to Test Step 3.

Result: A 7105-31 diagnostic code is active or logged.

Proceed to Test Step 17.

2. Check the NOx sensors for proper installation. NOx sensors Result : The “Aftertreatment System Functional Test”
completed successfully.
A. Turn the keyswitch to the OFF position.
Return the unit to service.
B. Verify that the sensors are located in the correct position.
Result : The “Aftertreatment System Functional Test” did
Note : The “Engine Out NOx” sensor wiring has a black sheath. not complete successfully and other codes were logged.
The “Tailpipe Out NOx” sensor wiring has a gray sheath.
Repair: Troubleshoot the logged codes. Refer to Trouble-
C. If the sensors are installed in the wrong positions, install the shooting, “Diagnostic Trouble Codes” for the code that
sensors in the correct positions. Refer to Disassembly and As- became active during the test.
sembly, Nitrogen Oxide Sensor - Remove and Install for the cor-
rect handling procedures.

D. Use the electronic service tool to perform the “Aftertreatment

System Functional Test” .

3. Check the Diesel Exhaust Fluid (DEF) Quality DEF Result : The DEF is not contaminated and the concentra-
tion is not within the acceptable range.
A. Measure the DEF quality. Refer to Systems Operation, Testing
and Adjusting, Diesel Exhaust Fluid Quality - Test for the correct Repair: Drain the DEF from the tank. Refill the tank with
procedure. DEF that meets ISO 22241 quality standards.

Proceed to Test Step 12.

Result : The DEF is not contaminated and the concentra-

tion is within the acceptable range.

Proceed to Test Step 4.

Result : The DEF is contaminated.

Contact the Dealer Solutions Network (DSN) for further

information.

(continued)

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Symptom Troubleshooting

(Table 97, contd)

Troubleshooting Test Steps Values Results

4. Determine the Diagnostic Code Diagnostic Result : A or 3516–11, 3516-15 or 3516-18 code is active
codes or logged.
A. Use the electronic service tool to check active or logged diag-
nostic codes. Repair: Replace the DEF tank header assembly. Refer to
Disassembly and Assembly, Manifold (DEF Heater) - Re-
move and Install for the correct procedure.

Proceed to Test Step 12.

Result : A 4364-18 code is active or logged.

Proceed to Test Step 5.

Result : The turbocharger wastegate actuator rod is de-

5. Check the Turbocharger Actuator Rod Turbocharger tached from the wastegate. The retaining clip is missing.
wastegate ac-
A. Check that the turbocharger wastegate actuator rod is securely tuator rod Contact the Dealer Solutions Network (DSN) for further
attached to the wastegate. information.

B. Use the electronic service tool to perform the “Air System Motor Result: There are active diagnostic codes that relate to
Valves Verification Test” . Check for active diagnostic codes that the turbocharger electronic wastegate.
relate to the turbocharger electronic wastegate.
Repair: Troubleshoot the active diagnostic codes. Refer
to Troubleshooting, Diagnostic Trouble Codes.

Proceed to Test Step 12.

Result : The turbocharger wastegate actuator rod is se-

curely attached to the wastegate. The retaining clip is se-
curely installed. The turbocharger electronic wastegate is
operating to specification.

Proceed to Test Step 6.

6. Inspect All the DEF Lines for Leaks Leaks Result: The lines are leaking, damaged, pinched, or
disconnected.
A. Turn the keyswitch to the ON position. Do not start the engine.
Repair: Make the necessary repairs.
B. Use the electronic service tool to perform the “DEF Dosing Sys-
tem Verification Test” to pressurize the system. Refer to Trouble- Proceed to Test Step 12.
shooting, “Service Tool Features” for more information.
Result: The lines are not leaking, damaged, pinched, or
C. Visually inspect all DEF lines from the DEF tank to the DEF in- disconnected.
jector. Look for pinched, damaged, or disconnected lines.
Proceed to Test Step 7.
D. Inspect the lines for leakage.

E. Turn the keyswitch to the OFF position.

(continued)

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(Table 97, contd)

Troubleshooting Test Steps Values Results

7. Perform a DEF Dosing System Accuracy Test DEF dosing sys- Result: The amount of DEF collected is within
tem accuracy specification.
test
A. Perform the “DEF Dosing System Accuracy Test” . Refer to Install the DEF injector. Refer to Disassembly and As-
Systems Operation, Testing and Adjusting, “Aftertreatment SCR sembly, “DEF Injector and Mounting - Remove and
System Dosing Test” for the correct procedure. Install”.

Proceed to Test Step 11.

Result: The amount of DEF collected is below

specification.

Proceed to Test Step 8.

Result: The amount of DEF collected is above

specification.

Repair: Install a replacement DEF injector. Refer to Dis-

assembly and Assembly, “DEF Injector and Mounting -
Remove and Install”.

Proceed to Test Step 12.

8. Check the DEF Pressure Line Restrictions, ob- Result: There are restrictions in the lines.
structions, or
A. Turn the keyswitch to the OFF position for 2 minutes. leaks Repair: Replace the line.

Note: The keyswitch must be OFF for 2 minutes to allow the DEF Proceed to Test Step 10.
pump to purge, reset the code, and reset the ECM.
Result: There are no restrictions in the lines.
B. Remove the DEF pressure line between the DEF pump and
the DEF injector. Refer to Disassembly and Assembly, Diesel Ex- Proceed to Test Step 9.
haust Fluid Lines - Remove and Install.

C. Inspect the line for obstructions. Flush the line with water or
low-pressure air, if necessary. Possible obstructions are ice, DEF
deposits, or debris.

9. Replace the DEF injector DEF Injector Result: The DEF injector was replaced. The DEF injector
was connected to the DEF pressure line and the electrical
A. Turn the keyswitch to the OFF position. connector, but the injector was not installed.

B. Remove the DEF injector. Refer to the Disassembly and As- Proceed to Test Step 10.
sembly, DEF Injector and Mounting - Remove and Install.

C. Connect the replacement DEF injector to the DEF pressure line

and the electrical connector.

Note : Do not install the injector until Step 11 has been

completed.

(continued)

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Symptom Troubleshooting

(Table 97, contd)

Troubleshooting Test Steps Values Results

10. Perform a DEF Dosing System Accuracy Test DEF dosing sys- Result: The amount of DEF collected is within
tem accuracy specification.
A. Perform the “DEF Dosing System Accuracy Test” . Refer to test
Systems Operation, Testing and Adjusting, “Aftertreatment SCR Install the DEF injector. Refer to Disassembly and As-
System Dosing Test” for the correct procedure. sembly, “DEF Injector and Mounting - Remove and
Install”.

Proceed to Test Step 12.

Result: The amount of DEF collected is below

specification.

Install the DEF injector. Refer to Disassembly and As-

sembly, “DEF Injector and Mounting - Remove and
Install”.

Install a replacement DEF pump. Refer to Disassembly

and Assembly, “Diesel Exhaust Fluid Pump - Remove
and Install”.

Proceed to Test Step 12.

11. Check for High Sulfur Fuel Fuel quality Result: High sulfur fuel is in use.
A. Ensure that the correct specification of fuel is being used. Refer
to the Operation and Maintenance Manual for the correct Repair: Drain the fuel tank, flush the fuel lines, and re-
specification. place the fuel filters.

Note: If fuel with a high sulfur content is used, this fault will reoc- Refill the fuel system with fuel of the correct specification.
cur and a replacement CEM may be required.
Proceed to Test Step 12.

Result: High Sulfur fuel is not in use.

Proceed to Test Step 12.

12. Perform the Aftertreatment Recovery Procedure Aftertreatment Result: The Aftertreatment Recovery Procedure com-
Recovery pleted successfully.
A. Connect to the electronic service tool. Procedure
Proceed to Test Step 13.
B. Perform the “Aftertreatment Recovery Procedure” .
Result: The Aftertreatment Recovery Procedure was not
successful.

Contact the Dealer Solutions Network (DSN).

(continued)

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(Table 97, contd)

Troubleshooting Test Steps Values Results

13. Perform an Aftertreatment System Functional Test Aftertreatment Result: The test completed successfully.
System Func-
A. Start the engine. tional Test Return the unit to service.

B. Connect to the electronic service tool. Result: A 4364-18 (E1309 (2)) with no ETI code is active.

C. Use the electronic service tool to perform the “Aftertreatment Proceed to Test Step 14.
System Functional Test” .
Result: A 4364-18 (E1309 (2)) with an ETI code of 1 is
active.

Proceed to Test Step 15.

Result: The test is unsuccessful. A 3516–11 diagnostic

code is still active.

If the DEF header has been replaced, contact the Dealer

Solutions Network (DSN).

14. Replace both NOx sensors NOx Sensors Result : The test completed successfully.

A. Turn the keyswitch to the OFF position. Return the unit to service.

B. Allow time for the exhaust system to cool down. Result : The test did not complete successfully.

C. Replace both NOx sensors. Contact the Dealer Solutions Network (DSN).

D. Use the electronic service tool to perform the “Aftertreatment

System Functional Test” .

15. Check the Coolant Level Coolant level Result : The coolant level is low and a leak is identified.

A. Check the coolant level in the engine cooling system. Refer to Repair: Repair the coolant leak and fill the coolant sys-
the Operation and Maintenance Manual, Coolant Level - Check. tem to the correct level.

Result : The coolant level is low and no leaks are

identified.

Repair: Fill the coolant system to the correct level.

Result : The coolant level is correct.

Proceed to Test Step 16.

(continued)

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Symptom Troubleshooting

(Table 97, contd)

Troubleshooting Test Steps Values Results

16. Inspect the NRS Cooler NRS cooler Result : An internal leak is identified in the NRS cooler.

A. Perform a leak test on the NRS cooler. Refer to Systems Oper- Repair:Install a replacement NRS cooler. Refer to Disas-
ation, Testing and Adjusting, Exhaust Cooler (NRS) - Test. sembly and Assembly, Exhaust Cooler (NRS) - Remove
and Install.

Use the electronic service tool to perform the “Aftertreat-

ment System Functional Test” .

If the “Aftertreatment System Functional Test” is passed,

return the unit to service.

If the “Aftertreatment System Functional Test” fails, con-

tact the Dealer Solutions Network (DSN).

Result : The NRS cooler does not have any internal leaks
and the fault is still present.

Contact the Dealer Solutions Network (DSN).

17. Check the Compatibility of the NOx Sensor Software Software Result : The NOx sensor software is not compatible with
the other modules on the CAN C data link.
A. Check the version of software in the NOx sensors.
Repair: If possible, update the software in the NOx
sensors.

If the software cannot be updated, replace both NOx

sensors.

If the fault is still present, contact the Dealer Solutions

Network (DSN).

i07582762

NRS Exhaust Gas Temperature

Is High

This procedure covers the following diagnostic

trouble codes:
Table 98
Diagnostic Codes for NRS Exhaust Gas Temperature Is High

J1939 Code Description Notes

412-15 Engine Exhaust Gas Recirculation Temperature : The exhaust gas temperature in the NRS is above the acceptable limit.
High - least severe
The engine has been running for at least 180 seconds.

There are no electrical faults on the circuit.

412-16 Engine Exhaust Gas Recirculation Temperature : The exhaust gas temperature in the NRS is above the acceptable limit.
High - moderate severity
The engine will be derated.

The engine has been running for at least 180 seconds.

There are no electrical faults on the circuit.

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Table 99
Associated Codes
J1939 Code Description

110-15 Engine Coolant Temperature : High - least se-

vere (1)

110-16 Engine Coolant Temperature : High - moderate

severity (2)

110-0 Engine Coolant Temperature : High - most se-

vere (3)

Probable Causes
• Diagnostic codes
• Coolant leak or low coolant level

• NRS cooler
• NRS Valve

Recommended Actions
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

Note: The procedures have been listed in order of

probability. Complete the procedures in order.

Table 100
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Diagnostic codes Result: A 412-X code and a 110-X code are present.

A. Download the Product Status Report with Histograms before Repair: Rectify the 110-X code. Refer to Troubleshooting,
troubleshooting or clearing any diagnostic codes. “Coolant Temperature Is High”.

Note: The downloaded information will be required by the Deal- Result: A 412-X code is present.
er Solutions Network (DSN) if troubleshooting assistance is
needed. Proceed to Test Step 2.

B. Use the electronic service tool to check for active or logged

codes.

2. Check Coolant Level Coolant level Result: The coolant level is low or a leak is identified.

A. Check the coolant level. Refer to the Operation and Mainte- Repair: Repair the coolant leak and replenish the coolant
nance Manual, Coolant Level - Check. system.

Result: The coolant level is correct.

Proceed to Test Step 3.

(continued)

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Symptom Troubleshooting

(Table 100, contd)

Troubleshooting Test Steps Values Results

3. Inspect the NRS Cooler for Leaks NRS cooler Result: The NRS cooler has internal leakage.

A. Perform a leak test on the NRS cooler. Refer to Systems Op- Repair: Replace the NRS cooler. Refer to Disassembly
eration, Testing, and Adjusting, “Exhaust Cooler (NRS) - Test”. and Assembly, “Exhaust Cooler (NRS) - Remove and
Install”.

Use the electronic service tool to clear all related diagnostic

codes and then run the engine and ensure that the fault
has been eliminated.

Result: The NRS cooler has no internal leakage. The fault

is still present.

Repair: Proceed to Test Step 4.

4. NRS Valve Pass Result: The “Air System Motor Valve Verification Test”
failed.
A. Use the electronic service tool to perform the “Air System
Motor Valve Verification Test” . Repair: Troubleshoot active diagnostic codes generated as
a result of the test.

Result: The “Air System Motor Valve Verification Test”

passed.

Contact the Dealer Solutions Network (DSN).

i07589421

NRS Mass Flow Rate Problem

This procedure covers the following diagnostic

trouble code:
Table 101
Diagnostic Trouble Code for NRS Mass Flow Rate Problem

J1939 Code Code Description Comments

Actual mass flow through the Exhaust Gas Recircula-
tion (EGR) does not match the desired mass flow.
Engine Exhaust Gas Recirculation (EGR) Mass Flow Rate : Not Re- The Electronic Control Module (ECM) has been pow-
2659-7
sponding Properly ered for at least 2 seconds.
The engine is running.
There are no active codes for the 5 VDC supply.

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Illustration 23 g06372057
(1) EGR temperature sensor (post-cooler)

Illustration 24 g06372072
(2) EGR cooler
(3) EGR valve
(4) EGR differential and inlet pressure sensor
(5) EGR temperature sensor (pre-cooler)

Table 102
Associated Codes
J1939 Code
412-15
412-16

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Symptom Troubleshooting

Probable Causes
• Diagnostic codes
• Electrical connectors and harness

• Air inlet and exhaust system

• NRS differential and inlet pressure sensor

• NRS temperature sensors

• NRS cooler

Recommended Actions
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

Note: The procedures have been listed in order of

probability. Complete the procedures in order.

Table 103
Troubleshooting Test Steps Values Results

1. Download Information Using the Electronic Service Tool Downloaded Result: The information was successfully saved.
information
A. Use the electronic service tool to download the “Product Sta- Proceed to Test Step 2.
tus Report” (PSR) with histograms before performing any trou-
bleshooting or clearing any diagnostic codes. Result: The electronic service tool information was not suc-
cessfully saved.
Note: The downloaded information will be required by the Deal-
er Solutions Network (DSN) if troubleshooting assistance is Contact the Dealer Solutions Network (DSN) for guidance.
required.

2. Create an Electronic Service Tool Snapshot Snapshot saved Result: The electronic service tool snapshot was success-
fully saved.
A. Select “Snapshot Viewer” on the electronic service tool, us-
ing menus: Information -> Snapshot -> Viewer Proceed to Test Step 3.

B. Select the event code and then click “View Graph” . Result: The electronic service tool snapshot was not suc-
cessfully saved.
C. Select the following parameter and then click OK.
Contact the DSN for guidance.
· Engine Speed

D. Select Save to "File to save" a Snapshot File (*.xml). This file

will contain all the data in the snapshot and not only the data
shown on the graph.
Note: The downloaded information will be required by the DSN
if troubleshooting assistance is required.

(continued)

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(Table 103, contd)

Troubleshooting Test Steps Values Results

3. Diagnostic Codes Diagnostic codes Result: An associated code is active or logged.

A. Use the electronic service tool to check for active or logged Repair: Troubleshoot associated codes before continuing
codes. with this procedure. Refer to Troubleshooting, Diagnostic
Trouble Codes or Troubleshooting, Event Codes for further
information.

Result: A diagnostic code for the NRS valve is active or

logged.

Repair: Rectify the NRS valve code. Refer to Troubleshoot-

ing, “Motorized Valve - Test”.

Result: A 2659-7 diagnostic code with no ETI is active.

Proceed to Test Step 4.

Result: A 2659-7 with an ETI of 1 is active.

Proceed to Test Step 8.

4. Inspect the Electrical Connectors and the Harness Connectors and Result: An electrical connector or a cable is not correctly
harness installed.
A. Turn the keyswitch to the OFF position.
Repair: Install the connector or cable correctly.
B. Inspect the connectors for the components in the NRS sys-
tem. Refer to Illustration 23 and Illustration 24 . Refer to Trou- Result: The harness is faulty.
bleshooting, “Electrical Connectors - Inspect”.
Repair: Install a replacement harness.
C. Perform a 30 N (6.7 lb) pull test on each of the wires in any
suspect connector. Result: The harness and connectors are OK.

D. Check that the ground connection on the ECM and the nega- Proceed to Test Step 5.
tive terminal on the battery are correctly installed.

E. Check the ground connection on the ECM for abrasions and

pinch points.

F. Check the harness for abrasion and pinch points from the
NRS components to the ECM.

G. Check that any suspect connector is installed correctly.

5. Check the Air Inlet and Exhaust System Air inlet and ex- Result: The air inlet system has a leak or is restricted.
haust system
A. Check the air inlet system for leaks and for restrictions. Repair: Clear any restrictions in the air inlet system.

B. Check the exhaust system for leaks and for restrictions. Repair any air leaks in the air inlet system.

Result: The exhaust system has a leak or is restricted.

Repair: Clear any restrictions in the exhaust system.

Repair any air leaks in the exhaust system.

If the fault is still present, proceed to Test Step 6.

(continued)

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Symptom Troubleshooting

(Table 103, contd)

Troubleshooting Test Steps Values Results

6. Check the NRS Differential and Inlet Pressure Sensor Pressure sensor Result: There is a restriction or a blockage in the sensor or
and pipes the sensor port.
A. Remove EGR differential and inlet pressure sensor (4). Re-
fer to Disassembly and Assembly, Pressure Sensor (Cooled Ex- Repair: If possible, clear the blockage or restriction. If nec-
haust Gas) - Remove and Install.. essary, replace parts.

B. Check the pressure sensor for restrictions or blockages. Result: There are no restrictions or blockages in the sensor
Check the sensor port for restrictions or blockages. or the sensor port.

Proceed to Test Step 7.

7. Check the NRS Temperature Sensors Temperature Result: The probe on the temperature sensor has exces-
sensor sive deposits.
A. Remove temperature sensor (1) and temperature sensor (5).
Refer to Disassembly and Assembly, “Temperature Sensor Repair: Carefully remove the deposits from the sensor
(Cooled Exhaust Gas) - Remove and Install”. probe. Make sure that the sensor probe is not damaged.

B. Check the sensor probes for excessive deposits. If the deposits cannot be easily removed, replace the tem-
perature sensor. Refer to Disassembly and Assembly,
“Temperature Sensor (Cooled Exhaust Gas) - Remove and
Install”.

Result: The probe on the temperature sensor does not

have excessive deposits.

Proceed to Test Step 8.

8. Check the Coolant Level Coolant level Result : The coolant level is low or a coolant leak is
identified.
A. Check the coolant level.
Rectify any coolant leaks and fill the coolant system to the
B. Check for leaks from the coolant system. correct level.

Result : The coolant level is normal and there are no cool-

ant leaks.

Proceed to Test Step 9.

9. Inspect the NRS Cooler NRS cooler Result : The NRS Cooler has internal leakage or fouling.

A. Perform a leak test on the NRS cooler. Refer to System Op- Repair: Replace the NRS Cooler. Refer to Disassembly
eration, Testing and Adjusting, Exhaust Cooler (NRS) - Test. and Assembly, Exhaust Cooler (NRS) - Remove and
Install.

Result : The NRS Cooler has no internal leakage or foul-

ing. The fault is still present.

If the fault is still present, contact the DSN and provide the
following information from Test Step 1 and Test Step 2:
• PSR and Histograms
• Snapshot data

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i08072993

Oil Consumption Is Excessive

Probable Causes
• Misreading oil level

• Oil leaks
• Engine crankcase breather

• Oil level
• Air intake and exhaust system

• Turbocharger
• Low compression (cylinder pressure)

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

Table 104
Troubleshooting Test Steps Values Results

1. Misreading Oil Level Oil level Result: The oil consumption is less than 0.08% of the fuel
consumption.
A. Accurately measure the consumption of oil and fuel over a
period of 50 engine hours. Oil consumption is within specification. Return the unit to
service

Result: The oil consumption is greater than 0.08% of the fuel

consumption.

Proceed to Test Step 2.

2. Oil Leaks Oil leaks Result: An oil leak is identified.

A. Check for evidence of oil leaks on the engine. Repair: Rectify the cause of the oil leak.

B. Check for evidence of oil in the coolant. Result: Oil is present in the coolant.

Repair: Refer to Troubleshooting, “Coolant Contains Oil”.

No oil leaks are identified

Proceed to Test Step 3.

(continued)

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Symptom Troubleshooting

(Table 104, contd)

Troubleshooting Test Steps Values Results

3. Engine Crankcase Breather Breather Result: The engine crankcase breather is blocked or
restricted.
A. Check the engine crankcase breather for blockage or
restrictions. Repair: Clear the blockage or restriction.

B. Check for excessive oil from the outlet of the breather. Result: Excessive oil is ejected from the outlet of the
breather.

Repair: Investigate the cause of the excessive oil content in

the breather flow.
Note: Some oil presence from the breather is normal.

Result: Little or no oil is ejected through the breather.

Proceed to Test Step 4.

4. Oil Level Oil level Result: The oil level in the engine is high.

A. Check for a high oil level in the engine. Repair: Make sure that the oil is not contaminated with fuel.
Refer to Troubleshooting, “Oil Contains Fuel”.

Make sure that the oil is not contaminated with coolant. Refer
to Troubleshooting, “Oil Contains Coolant”.

Remove the excess oil.

Result: The oil level is OK.

Proceed to Test Step 5.

5. Air Intake and Exhaust System Air intake and Result: The air filter restriction indicator has operated or the
exhaust system air filter is blocked.
A. Check the air filter restriction indicator, if equipped.
Repair: Make sure that the air filter is clean and serviceable.
Check the air intake and the exhaust system for the following If necessary, replace the air filter.
defects:
Result: The air intake or the exhaust system is blocked, re-
· Signs of dirt ingress stricted, or damaged.
· Blockages
· Restrictions Repair: Repair the air intake or the exhaust system, as
· Damage to the air intake and exhaust lines and hose required.

Result: The air intake or the exhaust system is OK.

Proceed to Test Step 6.

(continued)

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(Table 104, contd)

Troubleshooting Test Steps Values Results

6. Turbocharger Turbocharger Result: The oil drain for the turbocharger is blocked or
restricted.
Note: The turbocharger that is installed on this engine is a
non-serviceable item. If any mechanical fault exists, then the Repair: Remove the blockage or restriction. If necessary, re-
turbocharger must be replaced. place the oil drain line.

A. Check that the oil drain for the turbocharger is not blocked Result: The turbocharger has an internal oil leak.
or restricted.
Repair: Replace the turbocharger. Refer to Disassembly and
B. Remove the turbocharger compressor outlet duct to check Assembly, “Turbocharger - Remove” and Disassembly and
for evidence of a turbocharger internal oil leak. Assembly, “Turbocharger - Install”.

If the turbocharger is replaced, use the electronic service tool

to perform the “Turbocharger Wastegate Actuator Replace-
ment Reset” .
Use the electronic service tool to perform the “Air System Mo-
tor Valve Verification Test”
If equipped, check the front face of the Diesel Particulate Filter
(DPF) for contamination with oil.
If oil is found on the inlet face of the DPF, refer to Trouble-
shooting, “Exhaust System Contains Oil”.

Check that the repairs have eliminated the faults.

Result: The turbocharger is OK.

Proceed to Test Step 7.

7. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside the
compression specifications.
A. Perform a compression test. Refer to Systems Operation,
Testing and Adjusting, “Compression - Test”. Repair: Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown in the

following list:

· Loose glow plugs

· Worn piston
· Worn piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head

Result: The results of the compression test are OK.

Contact the Dealer Solutions Network (DSN).

i07590766 • Cylinder block

Oil Contains Coolant Recommended Actions

Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Probable Causes
• Engine oil cooler
• Cylinder head and gasket

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Table 105
Troubleshooting Test Steps Values Results

1. Engine Oil Cooler Oil cooler Result: Evidence of coolant in the oil system is identified.

A. Drain the engine lubricating oil and coolant from the en- Repair: Install a new oil cooler. Refer to Disassembly and As-
gine. Check for leaks in the oil cooler assembly. sembly, “Engine Oil Cooler - Remove” and Disassembly and
Assembly, “Engine Oil Cooler - Install” for the correct
procedure.

Result: There is no evidence of coolant in the oil system.

Proceed to Test Step 2.

2. Cylinder Head and Gasket Cylinder head Result: The cylinder head gasket is faulty or shows signs of
and gasket leakage.
A. Remove the cylinder head. Refer to Disassembly and As-
sembly, “Cylinder Head - Remove” for the correct procedure. Repair: Check for faults in the corresponding areas of the cyl-
Inspect the cylinder head gasket for faults and any signs of inder head and cylinder block.
leakage.
Result: The cylinder head is not within specification for
B. Check the cylinder head for flatness. Refer to Systems Op- flatness.
eration, Testing and Adjusting, “Cylinder Head - Inspect” for
the correct procedure. Repair: Install a new cylinder head. Refer to Disassembly and
Assembly, “Cylinder Head - Install” for the correct procedure.
C. Check the mating face of the cylinder head for faults and
signs of leakage. If a fault is found, replace the cylinder head. Result: The cylinder head shows signs of a fault or leakage.
If signs of leakage are found, determine the cause of the leak-
age. Refer to Systems Operation, Testing and Adjusting, “Cyl- Repair: Install a new cylinder head. Refer to Disassembly and
inder Head - Inspect” for the correct procedure. Assembly, “Cylinder Head - Install” for the correct procedure.

D. Check the internal core plugs in the cylinder head for signs Result: An internal core plug in the cylinder head shows signs
of leakage. of leakage.

Repair: Replace the faulty core plug.

Result: The cylinder head is OK.

Proceed to Test Step 3.

3. Cylinder Block Cylinder block Result: The top face of the cylinder block has a fault.

A. Inspect the top face of the cylinder block for faults and Repair: Replace the cylinder block.
signs of leakage.
Result: The top face of the cylinder block shows signs of
leakage.

Repair: Determine the cause of the leakage. Refer to Sys-

tems Operation, Testing and Adjusting, “Cylinder Block - In-
spect” for the correct procedure.

Result: The cylinder block is OK.

Repair: Install the cylinder head. Refer to Disassembly and

Assembly, “Cylinder Head - Install”.

Remove the oil filter element. Install a new engine oil filter ele-
ment. Fill the engine with clean engine oil to the correct level.
Refer to the Operation and Maintenance Manual, “Engine Oil
and Filter - Change” for more information.

(continued)

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(Table 105, contd)

Troubleshooting Test Steps Values Results

Fill the cooling system. Refer to the Operation and Mainte-

nance Manual for more information.

If coolant is found in the oil again, contact the Dealer Solutions

Network (DSN).

i08166738 Table 106

Minimum Oil Vis-
Oil Contains Fuel cosity at 100 °C
with Fuel Dilution
Viscosity Grade Action
Greater Than 4% as
Measured by a Gas
Chromatograph
Measuring Fuel Dilution
0W-40
Diesel fuel is chemically similar to the lubricants that
5W-40
are used in diesel engines. A slow fuel leak will blend 10W-40
12.0 cSt Investigate the
the fuel into the oil. Normal operating temperatures 15W-40 cause of fuel dilution
may cause volatile parts of the fuel to vaporize. The or reduce the engine
fuel that remains in the oil is less volatile. 0W-30 oil change interval.
5W-30 9.0 cSt
A closed cup flash test can be performed to detect 10W-30
fuel dilution. The flash test is designed to measure
the volatile parts of the fuel that are remaining in the
oil. Detecting less volatile fuel is difficult. The lack of Verifying Fuel Dilution
volatility reduces the accuracy of the flash test.
Always verify fuel dilution by the combination of a
Since the flash test does not accurately detect viscosity test and a gas chromatograph test that
fuel dilution, do not use the flash test as the only gives a result more than 4 percent.
measure of fuel dilution. Instead, verify the dilution
by the following methods:
Probable Causes
• Gas chromatograph fuel dilution test
• Fuel injector seals
• Oil viscosity
• Fuel injector tip
The test that uses a gas chromatograph is designed
to measure fuel dilution in crankcase oils. The gas • Shaft seal for the high-pressure fuel pump
chromatograph can identify the small chemical
differences between diesel fuel and lubricating oil. Recommended Actions
Even though the gas chromatograph provides a more
accurate measure of fuel dilution, always verify the Note: The procedures have been listed in order of
results with the viscosity test. probability. Complete the procedures in order.
A significant level of fuel dilution reduces oil viscosity.
If an unacceptable level of fuel dilution is suspected,
the kinematic viscosity of the oil must be measured.
Contact with high pressure fuel may cause fluid
Fuel dilution that is greater than 4 percent will usually penetration and burn hazards. High pressure fuel
cause viscosity that is less than the specified spray may cause a fire hazard. Failure to follow
viscosity grade. If the oil is still within the specified these inspection, maintenance and service in-
viscosity grade, fuel dilution is unlikely to have structions may cause personal injury or death.
reached an unacceptable level. Use the following
chart to determine if viscosity has reached the
minimum acceptable level. The guidelines of NOTICE
viscosity in the chart are slightly less than the limits of Contact with high-pressure fuel may cause personal
the SAE viscosity grades. However, these guidelines injury or death. Wait 10 minutes after the engine has
still provide adequate engine protection. stopped to allow fuel pressure to purge before any
service or repair is performed on the engine fuel
lines.

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Table 107
Troubleshooting Test Steps Values Results

1. Fuel Injector Seals Fuel injector Result: Injector seals are damaged.
seals
A. Check for signs of damage to the seals for the fuel Repair: Replace any damaged injector seals.
injectors.
Drain and refill the engine oil. Refer to the Operation and
Maintenance Manual, “Engine Oil and Filter - Change”.

Result: All injector seals are OK.

Proceed to Test Step 2.

2. Fuel Injector Tip Fuel injector tip Result: A fuel injector is damaged.

A. Check for signs of damage to the fuel injectors. Check the Repair: Replace the fuel injector. Refer to Disassembly and
fuel injector tip for cracks or breakage. Assembly, “Electronic Unit Injector - Remove” and Disassem-
bly and Assembly, “Electronic Unit Injector - Install”.

Drain and refill the engine oil. Refer to the Operation and
Maintenance Manual, “Engine Oil and Filter - Change”.

Result: All fuel injectors are OK.

Proceed to Test Step 3.

3. Shaft Seal for the High-Pressure Fuel Pump HP fuel pump Result: Fuel is leaking past the shaft seal for the high-pres-
shaft seal sure fuel pump.
A. Check for fuel leakage around the shaft seal for the high-
pressure fuel pump. Repair: There is a restriction in the return line to the fuel tank.
Investigate the cause of the restriction and then repair the fuel
line.

Replace the high-pressure fuel pump. Refer to Disassembly

and Assembly, “Fuel Injection Pump - Remove” and Disas-
sembly and Assembly, “Fuel Injection Pump - Install”.

Replace any filters and/or screens in the fuel system. Refer to

Operation and Maintenance Manual for further information.

Inspect the return pipe from the high-pressure fuel pump to

the fuel tank. replace any pipes that have been damaged or
distorted by hot fuel.

Drain and refill the engine oil. Refer to the Operation and
Maintenance Manual, “Engine Oil and Filter - Change”.

Result: The shaft seal for the high-pressure fuel pump is OK.

If the fault is still present, contact the Dealer Solutions Net-

work (DSN).

i07951879 Use this procedure if one of the following event codes

is active.
Oil Level Is Low

This procedure is only applicable to engines with an

oil level switch.

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Table 108
Diagnostic Trouble Codes for Oil Level Is Low

J1939 Code Code Description Comments

The engine oil level has dropped below the level of the switch for the
time specified in the ECM.
98–17 Engine Oil Level : Low - least severe (1)
The code is logged.
The engine is derated.

The engine oil level has dropped below the level of the switch for the
time specified in the ECM.
98-18 Engine Oil Level : Low - moderate severity (2)
The code is logged.
The engine is derated.

The engine oil level has dropped below the level of the switch for the
time specified in the ECM.
98-1 Engine Oil Level : Low - most severe (3)
The code is logged.
The engine is derated and may stop.

Probable Causes
• Low engine oil level
• Problem with an electrical connection or with the
wiring

• Faulty oil level switch

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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 M0095947-10 185
Symptom Troubleshooting

Table 109
Troubleshooting Test Steps Values Results

1. Low Engine Oil Level Engine oil level Result: The engine oil level is low.

A. Check the engine oil level. Refer to the Operation and Repair: Add engine oil, as necessary.
Maintenance Manual, “Engine Oil Level - Check”.
If engine oil consumption is considered excessive, refer to
Troubleshooting, “Oil Consumption Is Excessive”.

Proceed to Test Step 2.

2. Electrical Connections or Wiring Electrical connec- Result: There is a fault in an electrical connection or the
tors and wiring wiring.
A. Inspect the electrical connectors and all the wiring for the
switch. Refer to Troubleshooting, “Electrical Connectors - In- Repair: Repair or replace the faulty item.
spect” and refer to the electrical Schematic.
Result: The electrical connections and wiring are OK.

Proceed to Test Step 3.

3. Test the Oil Level Switch Oil level switch Result: The correct results are not obtained or if the switch
does not close.
Note: The engine oil level switch must be closed in order for
the engine to operate. The switch is normally open. The Repair: Replace the switch.
switch must be submerged in fluid to become closed.
Result: The correct results are obtained and the switch
A. Disconnect the switch and remove the switch. closes correctly.

B. Connect an ohmmeter to the switch terminals and meas- Contact the Dealer Solutions Network (DSN).
ure the continuity. The correct continuity for the normally
open switch is greater than 2k Ohms.

C. Continue to monitor the ohmmeter and submerge the

switch in water. The correct continuity for the closed switch is
less than 5 Ohms.

i07591682

Oil Pressure Is Low

NOTICE
Do not operate the engine with low oil pressure. En-
gine damage will result. If measured oil pressure is
low, discontinue engine operation until the fault is
corrected.

Note: Severe slopes can cause low oil pressure. If

the machine is operated on severe slopes, the oil
level in the engine crankcase must be at the “FULL”
mark on the dipstick. Refer to the Operation and
Maintenance Manual for details.

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 186 M0095947-10
Symptom Troubleshooting

Table 110
Diagnostic Code for Low Engine Oil Pressure

J1939 Code Code Description Comments

The Electronic Control Module (ECM) detects that the oil pres-
sure is low.

The engine is running.

100-1 Engine Oil Pressure : Low - most severe (3)
If equipped, the warning lamp will come on and the oil pres-
sure lamp will come on.

Probable Causes
• Engine oil level

• Oil specification
• Aerated oil

• Engine oil pressure

• Engine oil filter
• Engine oil cooler

• Fuel in the engine oil

• Piston cooling jets

• Engine oil suction tube

• Engine oil pump pressure relief valve

• Engine oil pump

• Bearing clearance

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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 M0095947-10 187
Symptom Troubleshooting

Table 111
Troubleshooting Test Steps Values Results

1. Engine Oil Level Oil level Result: The engine oil level is low.

A. Check the engine oil level. Repair: Fill the oil system to the full mark on the dipstick.

Result: The engine oil level is OK.

Proceed to Test Step 2.

2. Oil Specification Oil specification Result: An incorrect specification of engine oil is being used.

A. Check that engine oil of the correct specification is being Repair: Drain the oil system and refill the oil system with en-
used. Refer to the Operation and Maintenance Manual, “Refill gine oil of the correct specification. Refer to Operation and
Capacities and Recommendations”. Maintenance Manual, “Engine Oil and Filter - Change”.

Result: The engine contains oil of the correct specification.

Proceed to Test Step 3.

3. Aerated Oil Aeration Result: The oil is aerated.

A. Sample the engine oil for aeration. Proceed to Test Step 9.

Note: Foamy oil on the dipstick is a good indication of Result: The oil is not aerated.
aeration.
Proceed to Test Step 4.

4. Engine Oil Pressure Oil pressure Result: The oil pressure reading from the test gauge is great-
er than the closing pressure for the oil pressure switch.
A. Check the actual engine oil pressure with a calibrated test
gauge. Repair: Install a new oil pressure switch. Refer to Disassem-
The oil pressure switch should not close unless the pressure bly and Assembly, “Engine Oil Pressure Sensor - Remove
drops below 72 ± 17 kPa (10.4 ± 2.5 psi). and Install”.

Result: The oil pressure reading from the test gauge is less
than the closing pressure for the oil pressure switch.

Proceed to Test Step 5.

5. Engine Oil Filter Oil filter Result: The oil filter is blocked.

A. Remove the engine oil filter. Refer to the Operation and Repair: Investigate the cause of the filter blockage.
Maintenance Manual, “Engine Oil and Filter - Change”.
Install a new oil filter. Refer to the Operation and Maintenance
B. Inspect the engine oil filter for evidence of blockage. Manual, “Engine Oil and Filter - Change” for further
information.

Result: The oil filter is OK.

Repair: Install a new oil filter. Refer to the Operation and

Maintenance Manual, “Engine Oil and Filter - Change” for fur-
ther information.

Proceed to Test Step 6.

(continued)

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(Table 111, contd)

Troubleshooting Test Steps Values Results

6. Engine Oil Cooler Oil cooler Result: The oil cooler has signs of damage or restriction.

A. Check the oil cooler for signs of damage or restrictions. Repair: Install a new oil cooler. Refer to Disassembly and As-
sembly, “Engine Oil Cooler - Remove” and Disassembly and
Assembly, “Engine Oil Cooler - Install”.

Result: The oil cooler is OK.

Proceed to Test Step 7.

7. Fuel in the Engine Oil Oil Result: The oil contains fuel.
contamination
A. Check fuel contamination of the engine oil. Refer to Trou- Repair: Refer to Troubleshooting, “Oil Contains Fuel”.
bleshooting, “Oil Contains Fuel”.
Result: The oil is not contaminated.

Proceed to Test Step 8.

8. Piston Cooling Jets Piston cooling Result: A piston cooling jet is cracked, damaged, or missing.
jets
A. Inspect the piston cooling jets for cracks, damage, or miss- Repair: Install a new piston cooling jet. Refer to Disassembly
ing jets. and Assembly, “Piston Cooling Jets - Remove and Install”.

Result: The piston cooling jets are OK.

Proceed to Test Step 9.

9. Engine Oil Suction Tube Oil suction tube Result: The inlet screen on the oil suction tube is blocked with
debris.
A. Check the inlet screen on the oil suction tube and remove
any material that may be restricting oil flow. Repair: Remove the debris from the inlet screen. Attempt to
identify the source of the debris.
B. Check the joints of the oil suction tube for cracks or a dam-
aged joint. Result: The oil suction tube is cracked.

Note: Cracks or damage may allow air leakage into the sup- Repair: Install a new oil suction tube.
ply to the oil pump.
Result: The oil suction tube is OK.

Proceed to Test Step 10.

10. Engine Oil Pump Pressure Relief Valve Oil pump PRV Result: A component in the pressure relief valve is not within
specification.
A. Inspect the components of the pressure relief valve for ex-
cessive wear or damage. Repair: Repair or replace the pressure relief valve, as neces-
sary. Refer to Disassembly and Assembly, “Engine Oil Relief
Valve - Remove and Install”.

Result: The pressure relief valve is OK.

Proceed to Test Step 11.

(continued)

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 M0095947-10 189
Symptom Troubleshooting

(Table 111, contd)

Troubleshooting Test Steps Values Results

11. Engine Oil Pump Oil pump Result: A component in the oil pump is not within
specification.
A. Inspect the components of the engine oil pump for exces-
sive wear. Repair: Repair the oil pump or replace the oil pump, if neces-
sary. Refer to Disassembly and Assembly, “Engine Oil Pump -
Remove” and Disassembly and Assembly, “Engine Oil Pump -
Install”.

Result: The oil pump is OK.

Proceed to Test Step 12.

12. Bearing Clearance Bearing Result: An engine bearing is not within specification.
clearance
A. Inspect the engine components for excessive bearing Repair: Install a new bearing. Refer to Disassembly and
clearance or damaged bearings. Inspect the following compo- Assembly.
nents for excessive bearing clearance:
Result: All engine bearings are within specification.
· Crankshaft main bearings
· Connecting rod bearings Contact the Dealer Solutions Network (DSN).
· Camshaft front bearing
· Idler gear bearing

i08166748

Power Is Intermittently Low or

Power Cutout Is Intermittent

Note: Use this procedure only if the engine does not

shut down completely.

Probable Causes
• Diagnostic codes
• Electrical connectors

• ECM connection
• Intake manifold pressure

• Fuel supply

Recommended Actions
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

Note: The procedures have been listed in order of

probability. Complete the procedures in order.

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 190 M0095947-10
Symptom Troubleshooting

Table 112
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Diagnostic Result: There are active or logged codes.

codes
A. Establish communication between the electronic service Repair: Troubleshoot any codes before continuing with this
tool and the Electronic Control Module (ECM). Refer to Trou- procedure.
bleshooting, “Electronic Service Tools”, if necessary.
Result: There are no active or logged codes.
B. Download the Product Status Report (PSR) with Histo-
grams before performing any troubleshooting or clearing any Proceed to Test Step 2.
diagnostic codes.

Note: The downloaded information will be required by the

Dealer Solutions Network (DSN) if troubleshooting assistance
is needed.

C. Use the electronic service tool to check for active or logged

codes.

2. Electrical Connectors Electrical Result: An electrical connector is damaged.

connectors
A. Check all electrical connectors for damage. Refer to Trou- Repair: Repair the electrical connector or replace the electri-
bleshooting, “Electrical Connectors - Inspect”. cal connector.

B. Make sure that all the connector seals are in place and that Result: A connector seal is displaced or missing or an electri-
the connectors have been correctly installed. cal connector is not correctly installed.

Repair: Repair the electrical connector or replace the electri-

cal connector.

Result: All electrical connectors are OK.

Proceed to Test Step 3.

3. ECM Connection ECM connection Result: An ECM connector is not correctly installed.

Repair: Repair the electrical connector or replace the electri-

A. Check that the P2/J2 and P1/J1 connectors are correctly cal connector.
installed.
Result: Both ECM connectors are correctly installed.
Note: If a fault is suspected with the ECM power or ground
connections, refer to Troubleshooting, “Electrical Power Sup- Proceed to Test Step 4.
ply - Test”.

(continued)

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 M0095947-10 191
Symptom Troubleshooting

(Table 112, contd)

Troubleshooting Test Steps Values Results

4. Intake Manifold Pressure Intake manifold Result: The intake manifold pressure does not read
0 ± 0.5 kPa (0 ± 0.07 psi).
A. Use the electronic service tool to verify the intake manifold
pressure. Repair: Refer to Troubleshooting, “Intake Manifold Air Pres-
sure Is Low”.
Turn the start switch to the ON position.
Result: The intake manifold pressure reads 0 ± 0.5 kPa
The intake manifold pressure must read 0 ± 0.5 kPa (0 ± 0.07 psi).
(0 ± 0.07 psi).
Proceed to Test Step 5.

5. Fuel Supply Fuel system Result: The fuel supply is not OK.

A. Visually check the fuel level in the fuel tank. Do not rely on Repair: Repair the fuel system or replace the fuel system
the fuel gauge only. components, as necessary.

B. Ensure that the vent in the fuel cap is not filled with debris. Result: The fuel supply is OK.

C. Ensure that the fuel supply valve (if equipped) is in the full Proceed to Test Step 6.
OPEN position.

D. If the temperature is below 0 °C (32 °F), check for solidi-

fied fuel (wax).

E. Check the primary filter/water separator for water in the

fuel.

F. Check for fuel supply lines that are restricted.

G. Check that the low-pressure fuel lines are tight and se-
cured properly.

H. Check that the Electric Priming Pump (EPP) is operating

correctly.

I. Replace any filters and/or screens in the fuel system. Refer

to Operation and Maintenance Manual for further information.

J. Check the diesel fuel for contamination. Refer to Systems

Operation, Testing and Adjusting, “Fuel Quality - Test”.

K. Check for air in the fuel system. Refer to Systems Opera-

tion, Testing and Adjusting, “Air in Fuel - Test”.

L. Ensure that the fuel system has been primed. Refer to Sys-
tems Operation, Testing and Adjusting, “Fuel System -
Prime”.

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Symptom Troubleshooting

i07609694

SCR Catalyst Has Incorrect Inlet

Temperature

Table 113
Diagnostic Trouble Code for SCR Catalyst Has Incorrect Inlet Temperature

J1939 Codes Code Description Comments

The aftertreatment SCR catalyst intake gas temperature sensor has de-
tected an implausible change in temperature.
Aftertreatment #1 SCR Catalyst Intake Gas Tem-
4360–10
perature : Abnormal Rate of Change

The aftertreatment SCR catalyst intake gas temperature sensor has de-
tected that the SCR intake temperature is above the normal operating
Aftertreatment #1 SCR Catalyst Intake Gas Tem-
4360-16 range.
perature : High - moderate severity (2)

ECM detects that the SCR catalyst intake temperature is below the ac-
ceptable range.
Aftertreatment #1 SCR Catalyst Intake Gas Tem-
4360-17 The code is logged.
perature : Low - least severe (1)

The aftertreatment SCR catalyst intake gas temperature sensor has de-
tected that the SCR intake temperature is far below the normal operating
Aftertreatment #1 SCR Catalyst Intake Gas Tem-
4360-18 range.
perature : Low - moderate severity (2)

Follow the troubleshooting procedure to identify the root cause of the fault.

Complete the procedure in the order in which the

steps are listed.

Probable causes
• Diagnostic codes
• High exhaust temperature

• Exhaust system
Note: The procedures have been listed in order of
probability. Complete the procedure in the order in
which the steps are listed.

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 M0095947-10 193
Symptom Troubleshooting

Table 114
Troubleshooting Test Steps Values Results

1. Check for Diagnostic Trouble Codes Diagnostic trou- Result: A 4360 code is active or recently logged.
ble codes
A. Turn the keyswitch to the ON position. Do not start the engine. Proceed to Test Step 2.

B. Connect to the electronic service tool. Result: An associated code other than 4360 is active or
recently logged.
C. Check for associated diagnostic trouble codes.
Repair: Troubleshoot the logged or active code. Refer to
Troubleshooting, “Diagnostic Trouble Codes”.

Result: No codes are active or recently logged.

Proceed to Test Step 5.

2. Check the Operation of the SCR Catalyst Inlet Temperature Sensor Result : The value of the SCR catalyst inlet temperature
Sensor sensor is within ±9° C (15° F) of ambient temperature.

Note : Only perform this step on a cold engine. Repair : Reinstall the sensor. torque the sensor to the
proper specification.
A. Remove the SCR catalyst inlet temperature sensor and allow
the sensor to rest in ambient air for 2 minutes. For a 4360-16 code proceed to Test Step 3.

B. Connect the electronic service tool to the diagnostic connector. For a 4360-17 or 4360-18 code proceed to Test Step 4.

C. Monitor the value of the SCR catalyst inlet temperature sensor Result : The value of the SCR catalyst inlet temperature
on the electronic service tool. sensor is not within ±9° C (15° F) of ambient
temperature.

Repair : Replace the SCR catalyst inlet temperature sen-

sor. Refer to the Disassembly and Assembly manual for
more information.

Proceed to Test Step 5.

3. Check for Cause of High Temperature High Result: There has been an exothermic event in the DOC
temperature or DPF.
A. Check for evidence of an exothermic event in the DOC and
DPF. Repair: Replace the Clean Emissions Module (CEM).

B. Check for evidence of excessive fuel reaching the DOC or DPF Result: There is evidence of excessive fuel reaching the
DOC or DPF.

Repair: Investigate the cause of the excess fuel.

(continued)

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 194 M0095947-10
Symptom Troubleshooting

(Table 114, contd)

Troubleshooting Test Steps Values Results

4. Check the Exhaust System Exhaust System Result: The exhaust system or the CEM has a gas leak.

A. Check the exhaust system for gas leaks between the turbo- Repair: Make the necessary repairs.
charger and the exhaust tail pipe.
Proceed to Test Step 5.
B. Check for gas leaks around the following items in the Clean
Emissions Module (CEM): Result: The exhaust system insulation is damaged or
missing.
· Temperature sensors
· SCR intake NOx sensor Repair: Make the necessary repairs.
· DEF injector
Proceed to Test Step 5.
C. Check for missing or damaged exhaust system insulation.
Result: There is excessive cooling air flow over the
D. Make sure that the cooling air flow over the CEM is not exces- CEM.
sive for the ambient conditions.
Repair: Reduce the cooling air flow. If necessary, consult
the Dealer Solutions Network (DSN) for further advice.

Proceed to Test Step 5.

5. Inspect the DPF Damaged DPF Result: The DPF has a damaged or missing DPF core.
core
A. Inspect the inlet of the DPF. Inspect the DPF for a damaged or Repair: Repair the damaged DPF or missing DPF core.
missing DPF core. Proceed to Test Step 6.

6. Check the SCR Catalyst Temperature Manual hydro- Result: The “Manual Hydrocarbon Dosing Capability
carbon dosing Test” completed successfully.
A. Connect to the electronic service tool. capability test
Return the unit to service.
B. Run the engine.
Result: The “Manual Hydrocarbon Dosing Capability
C. Perform the “Manual Hydrocarbon Dosing Capability Test” . Test” failed. An error identifier is generated by the elec-
tronic service tool.

Repair: Troubleshoot the error identifier. Refer to Trou-

bleshooting, “Service tool Error Identifiers”. Repeat Test
Step 4.

Result: The “Manual Hydrocarbon Dosing Capability

Test” failed. No error identifiers are generated.

Contact the Dealer Solutions Network (DSN).

i07609709 Inducement strategies are control actions required by

EPA/ARB Tier 4 and EU Stage IV regulations. An
SCR Warning System Problem inducement strategy ensures prompt correction of
various failures in the engine NOx emission control
system. The strategy requires actions to limit engine
performance and defines required the following
indications when the control actions are imposed:
Operator Level Inducement
Inducements are engine derates or other actions • Lamps
intended to prompt the operator to repair or maintain • Messages
the emission control system.
• Audible alarms

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 M0095947-10 195
Symptom Troubleshooting

Table 115
Diagnostic Trouble Codes for SCR Warning System Problem

J1939 Code Description Notes

This code is a Level 1 inducement associated with an emission acti-

Aftertreatment SCR Operator Inducement Severity :
5246-15 vated fault.
High - least severe (1)
The Emissions System Malfunction Lamp is on.

This code is a Level 2 inducement associated with an emission acti-

vated fault.
Aftertreatment SCR Operator Inducement Severity :
5246-16 The Emissions System Malfunction Lamp is on and the Action Lamp
High - moderate severity (2)
is flashing.
The engine is derated.

This code is a Level 3 inducement associated with an emission acti-

vated fault.
Aftertreatment SCR Operator Inducement Severity : The Emissions System Malfunction lamp is on, the Action lamp is
5246-0
High - most severe (3) flashing, and the warning horn may sound.
The engine is derated.
The engine may stop.

Associated Codes
Troubleshoot any associated diagnostic codes listed
in Table 116 that are present. Refer to “Inducement
Type” in Table 116 for the correct Inducement table.
Table 116
Associated Codes
J1939 Code Code Description Inducement Type

EGR Control Actuator Position Sensor: Voltage NRS Inducement

27–3
Above Normal
EGR Control Actuator Position Sensor: Voltage Be- NRS Inducement
27–4
low Normal

411–3 Engine EGR Delta Pressure: Voltage Above Normal NRS Inducement

411–4 Engine EGR Delta Pressure: Voltage Below Normal NRS Inducement

1235-9 J1939 Network #3 : Abnormal Update Rate DEF Quality/Tampering/Dosing Interruption

1235-14 J1939 Network #3 : Special Instruction DEF Quality/Tampering/Dosing Interruption

1761-1 Catalyst Tank Level : Low - most severe (3) DEF Tank Level Inducement

1761-12 Catalyst Tank Level : Failure DEF Tank Level Inducement

1761-17 Catalyst Tank Level : Low - least severe (1) DEF Tank Level Inducement

1761-18 Catalyst Tank Level : Low - moderate severity (2) DEF Tank Level Inducement

Engine Exhaust Gas Recirculation (EGR) Mass NRS Inducement

2659-7
Flow Rate : Not Responding Properly

Engine Exhaust Gas Recirculation (EGR) Valve NRS Inducement

2791-5
Control : Current Below Normal
Engine Exhaust Gas Recirculation 1 Valve 1 Control NRS Inducement
2791–7
1: Not Responding Properly

3031-12 Catalyst Tank Temperature : High : Failure DEF Quality/Tampering/Dosing Interruption

Catalyst Tank Temperature : High - moderate se- DEF Quality/Tampering/Dosing Interruption

3031-16
verity (2)

(continued)

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 196 M0095947-10
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(Table 116, contd)

Catalyst Tank Temperature : Low - moderate DEF Quality/Tampering/Dosing Interruption
3031-18
severity

3216-12 Aftertreatment #1 Intake NOx : Failure DEF Quality/Tampering/Dosing Interruption

Aftertreatment #1 Intake O2 : High - moderate se- DEF Quality/Tampering/Dosing Interruption

3217-16
verity (2)

3226-12 Aftertreatment #1 Outlet NOx : Failure DEF Quality/Tampering/Dosing Interruption

Aftertreatment #1 Outlet O2 : High - moderate se- DEF Quality/Tampering/Dosing Interruption

3227-16
verity (2)

Engine Exhaust Gas Recirculation 1 Intake Pres- NRS Inducement

3358–3
sure: Voltage Above Normal

Engine Exhaust Gas Recirculation 1 Intake Pres- NRS Inducement

3358–4
sure: Voltage Below Normal

3361-5 Catalyst Dosing Unit : Current Below Normal DEF Quality/Tampering/Dosing Interruption

3361-6 Catalyst Dosing Unit : Current Above Normal DEF Quality/Tampering/Dosing Interruption

3361-7 Catalyst Dosing Unit : Not Responding Properly DEF Quality/Tampering/Dosing Interruption

3363-5 Catalyst Tank Heater : Current Below Normal DEF Quality/Tampering/Dosing Interruption

3363-6 Catalyst Tank Heater : Current Above Normal DEF Quality/Tampering/Dosing Interruption

3509–3 Sensor Supply Voltage 1 : Voltage Above Normal DEF Quality/Tampering/Dosing Interruption

3509–4 Sensor Supply Voltage 1 : Voltage Below Normal DEF Quality/Tampering/Dosing Interruption

3510–3 Sensor Supply Voltage 2 : Voltage Above Normal DEF Quality/Tampering/Dosing Interruption

3510–4 Sensor Supply Voltage 2 : Voltage Below Normal DEF Quality/Tampering/Dosing Interruption

Aftertreatment #1 DEF Concentration : Erratic, Inter- DEF Quality/Tampering/Dosing Interruption

3516-2
mittent, or Incorrect

3516-12 Aftertreatment #1 DEF Concentration : Failure DEF Quality/Tampering/Dosing Interruption

Aftertreatment 1 Diesel Exhaust Fluid Concentration DEF Quality/Tampering/Dosing Interruption

3516-18
: Low - moderate severity (2)

Aftertreatment #1 SCR Dosing Reagent Absolute DEF Quality/Tampering/Dosing Interruption

4334-3
Pressure : Voltage Above Normal

Aftertreatment #1 SCR Dosing Reagent Absolute DEF Quality/Tampering/Dosing Interruption

4334-4
Pressure : Voltage Below Normal

Aftertreatment 1 Diesel Exhaust Fluid Doser Abso- DEF Quality/Tampering/Dosing Interruption

4334–7
lute Pressure: Not Responding Properly

Aftertreatment #1 SCR Dosing Reagent Absolute DEF Quality/Tampering/Dosing Interruption

4334-16
Pressure : High - moderate severity (2)

Aftertreatment #1 SCR Dosing Reagent Absolute DEF Quality/Tampering/Dosing Interruption

4334-18
Pressure : Low - moderate severity (2)

Aftertreatment #1 DEF Doser #1 Temperature : Ab- DEF Quality/Tampering/Dosing Interruption

4337–8
normal Frequency, Pulse Width, or Period

Aftertreatment #1 SCR Catalyst Reagent Line Heat- DEF Quality/Tampering/Dosing Interruption

4354-5
er #1 : Current Below Normal
Aftertreatment #1 SCR Catalyst Reagent Line Heat- DEF Quality/Tampering/Dosing Interruption
4354-6
er #1 : Current Above Normal

(continued)

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 M0095947-10 197
Symptom Troubleshooting

(Table 116, contd)

Aftertreatment #1 SCR Catalyst Reagent Line Heat- DEF Quality/Tampering/Dosing Interruption
4355-5
er #2 : Current Below Normal
Aftertreatment #1 SCR Catalyst Reagent Line Heat- DEF Quality/Tampering/Dosing Interruption
4355-6
er #2 : Current Above Normal
Aftertreatment #1 SCR Catalyst Reagent Line Heat- DEF Quality/Tampering/Dosing Interruption
4356-5
er #3 : Current Below Normal
Aftertreatment #1 SCR Catalyst Reagent Line Heat- DEF Quality/Tampering/Dosing Interruption
4356-6
er #3 : Current Above Normal
Aftertreatment #1 SCR Catalyst Intake Gas Temper- DEF Quality/Tampering/Dosing Interruption
4360-3
ature : Voltage Above Normal

Aftertreatment #1 SCR Catalyst Intake Gas Temper- DEF Quality/Tampering/Dosing Interruption

4360-4
ature : Voltage Below Normal

Aftertreatment #1 SCR Catalyst Intake Gas Temper- DEF Quality/Tampering/Dosing Interruption

4360–16
ature : High - moderate severity (2)

Aftertreatment #1 SCR Catalyst Intake Gas Temper- DEF Quality/Tampering/Dosing Interruption

4360-18
ature : Low - moderate severity (2)

Aftertreatment #1 SCR Catalyst Conversion Effi- DEF Quality/Tampering/Dosing Interruption

4364-2
ciency : Erratic, Intermittent, or Incorrect

Aftertreatment #1 SCR Catalyst Conversion Effi- DEF Quality/Tampering/Dosing Interruption

4364-18
ciency : Low - moderate severity (2)

Aftertreatment #1 Diesel Exhaust Fluid Pump Motor DEF Quality/Tampering/Dosing Interruption

4374-5
Speed : Current Below Normal

Aftertreatment #1 Diesel Exhaust Fluid Pump Motor DEF Quality/Tampering/Dosing Interruption

4374-6
Speed : Current Above Normal

Aftertreatment #1 DEF Pump #1 Motor Speed : Ab- DEF Quality/Tampering/Dosing Interruption

4374–8
normal Frequency, Pulse Width, or Period

Aftertreatment #1 DEF Return Valve : Current Below DEF Quality/Tampering/Dosing Interruption

4376–5
Normal
Aftertreatment #1 DEF Return Valve : Not Respond- DEF Quality/Tampering/Dosing Interruption
4376–7
ing Properly

Engine Exhaust Gas Recirculation 1 Cooler Intake NRS Inducement

4750–3
Temperature: Voltage Above Normal

Engine Exhaust Gas Recirculation 1 Cooler Intake NRS Inducement

4750–4
Temperature: Voltage Below Normal

Aftertreatment Diesel Exhaust Fluid Dosing Unit DEF Quality/Tampering/Dosing Interruption

5392-31
Loss of Prime
Aftertreatment Diesel Particulate Filter Temperature DEF Quality/Tampering/Dosing Interruption
5742–12
Sensor Module : Failure
Aftertreatment 1 SCR Temperature Sensor Module : DEF Quality/Tampering/Dosing Interruption
5743–12
Failure
Engine Exhaust NOx Level Sensor Power Supply: DEF Quality/Tampering/Dosing Interruption
5758-11
Other Failure Mode
Aftertreatment #1 Outlet #1 NOx Level Sensor DEF Quality/Tampering/Dosing Interruption
5759-11
Power Supply : Other Failure Mode

Aftertreatment #1 DEF Dosing Unit Heater Temper- DEF Quality/Tampering/Dosing Interruption

5798–7
ature : Not Responding Properly

(continued)

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(Table 116, contd)

Aftertreatment #1 Diesel Exhaust Fluid Dosing Con- DEF Quality/Tampering/Dosing Interruption
5965-5
trol Unit Relay : Current Below Normal

Aftertreatment #1 Diesel Exhaust Fluid Dosing Con- DEF Quality/Tampering/Dosing Interruption

5965-6
trol Unit Relay : Current Above Normal

Table 117
Troubleshooting Test Steps Values Results

1. Check for Associated Codes Associated Result: Associated codes are logged or active.
Codes
A. Use the electronic service tool to check for active diagnostic Repair: Troubleshoot the associated codes. Refer to
codes. Troubleshooting, “Diagnostic Trouble Codes” for the prop-
er procedure.

Proceed to Test Step 2.

2. “ Aftertreatment System Functional Test”” Inducements Result: The inducements have been cleared.

A. Use the electronic service tool to perform the “Aftertreatment Return the unit to service.
System Functional Test” . This test will clear the inducement if all
associated diagnostic codes have been cleared. Result: The inducements have not cleared.

Contact the Dealer Solutions Network (DSN).

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 M0095947-10 199
Symptom Troubleshooting

World-Wide Reduced Performance

Setting
Table 118
World-Wide Reduced Performance Setting

Category 1 Fault (Tampering Dosing Interruption and Quality)

- Normal operation Level 1 Level 2 Level 3 Override

Inducement Time None 2.5 Hours 70 minutes 50 Percent torque Cycling the keyswitch
First Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then
the repeat occurrence inducement time will be triggered.
The override can only be used once

Inducement Time None 5 minutes 75 Percent torque 50 Percent torque Cycling the keyswitch
Repeat Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
Inducement None None None
Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will be
on solid
Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

Table 119
World-Wide Reduced Performance Setting

Category 2 Fault (Non-Tampering Dosing and Interruption)

- Normal operation Level 1 Level 2 Level 3 Override

Inducement Time None 10 Hours 10 Hours 50 Percent torque Cycling the keyswitch
First Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then
the repeat occurrence inducement time will be triggered.
The override can only be used once

Inducement Time None None 2 Hours 50 Percent torque Cycling the keyswitch
Repeat Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
Inducement None None 75 Percent of torque

Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will be
on solid
Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

Table 120
World-Wide Reduced Performance Setting

Category 3 Fault (Non-Tampering NOx Control Monitoring and Impeded EGR)

- Normal operation Level 1 Level 2 Level 3 Override

(continued)

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 200 M0095947-10
Symptom Troubleshooting

(Table 120, contd)

Inducement Time None 36 Hours 64 Hours 50 Percent torque Cycling the keyswitch
First Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then
the repeat occurrence inducement time will be triggered.
The override can only be used once

Inducement Time None None 5 Hours 50 Percent torque Cycling the keyswitch
Repeat Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
Inducement None None 75 Percent of torque

Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will be
on solid
Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

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 M0095947-10 201
Symptom Troubleshooting

World-Wide Reduce Time Setting

Table 121
World-Wide Reduced Time Setting

Category 1 Fault (Tampering Dosing Interruption and Quality)

- Normal operation Level 1 Level 2 Level 3 Override

Inducement Time None 2.5 Hours 70 minutes 50 Percent torque Cycling the keyswitch
First Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then
the repeat inducement time will be triggered.
The override can only be used once.

Inducement Time None 5 minutes 5 minutes 50 Percent torque Cycling the keyswitch
Repeat Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
Inducement None None None
Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will
activate
Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

Table 122
World-Wide Reduced Time Setting

Category 2 Fault (Non-Tampering Dosing Interruption)

- Normal operation Level 1 Level 2 Level 3 Override

Inducement Time None 5 Hours 5 Hours 50 Percent torque Cycling the keyswitch
First Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then
the repeat inducement time will be triggered.
The override can only be used once.

Inducement Time None None 1 Hour 50 Percent torque Cycling the keyswitch
Repeat Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
Inducement None None None
Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will
activate
Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

Table 123
World-Wide Reduced Time Setting

Category 3 Fault (Non-Tampering NOx Control Monitoring and Impeded EGR)

- Normal operation Level 1 Level 2 Level 3 Override

Inducement Time None 18 Hours 18 Hours 50 Percent torque Cycling the keyswitch
First Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power

(continued)

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 202 M0095947-10
Symptom Troubleshooting

(Table 123, contd)

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then
the repeat inducement time will be triggered.
The override can only be used once.

Inducement Time None None 108 Minutes 50 Percent torque Cycling the keyswitch
Repeat Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
Inducement None None None
Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will
activate
Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

World-Wide DEF Level Warnings

Two options are available but only one option will be
enabled.
• The low-level warning lamp will operate when DEF
level reaches the trigger point of below 20 percent.

• At Level 1 the low-level warning lamp in the DEF

gauge will illuminate and the emission malfunction
lamp will be on solid.
• At Level 2 the low-level warning lamp for the DEF
is active and the emission malfunction lamp will
flash.
• At Level 3 all level 2 warning lamps are active,
plus the stop lamp will become active. The engine
will shut down or will only operate at 1000 RPM.
Filling the DEF tank will remove the warning from the
system.
Table 124
World-Wide DEF Level Option 1

- Normal operation Initial indication Level 1 Level 2 Level 3

Inducement Trigger Above 19 percent Below 19 percent Below 12.5 percent 0 Percent reading Empty tank

Inducement None None None Engine may be de- The engine may be
rated by 25 percent derated by 50 percent
torque torque.
A shutdown or low
idle only will be en-
forced after 5
minutes.
Notification None Low-level lamp Low-level lamp Low-level lamp Low-level lamp
illuminated illuminated illuminated illuminated
Emission malfunction Emission malfunction Emission malfunction
lamp on solid lamp flashing lamp flashing
Stop lamp on solid

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 M0095947-10 203
Symptom Troubleshooting

Table 125
World-Wide DEF Level Option 2

- Normal operation Initial indication Level 1 Level 2 Level 3

Inducement Trigger Above 19 percent Below 19 percent Below 12.5 percent 6 Percent reading 0 Percent reading

Inducement None None None None The engine may be

derated by 50 percent
torque
A shutdown or low
idle only will be en-
forced after 5
minutes.
Notification None Low-level lamp Low-level lamp Low-level lamp Low-level lamp
illuminated illuminated illuminated illuminated
Emission malfunction Emission malfunction Emission malfunction
lamp on solid lamp flashing lamp flashing
Stop lamp on solid

i07713697

Transmission Oil Temperature

Is High

Use this procedure to troubleshoot high transmission

oil temperature. Use this procedure if one of the
following event codes is active.
Table 126
Event Codes for High Transmission Oil Temperature

J1939 Code and Description Conditions which Generate this Code System Response
177–0 The transmission oil temperature is above the
Transmission Oil Temperature : High - most se- programmed trip point for the specified delay The code is logged.
vere (3) time.

177-15 The transmission oil temperature is above the

Transmission Oil Temperature : High - least se- programmed trip point for the specified delay The code is logged.
vere (1) time.

177-16 The transmission oil temperature is above the

Transmission Oil Temperature : High - moder- programmed trip point for the specified delay The code is logged.
ate severity (2) time.

Probable Causes
• Transmission oil level

• Transmission oil cooler

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in the order of
the listed test steps.

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 204 M0095947-10
Symptom Troubleshooting

Table 127
Troubleshooting Test Steps Values Results

1. Check the Transmission Oil Level Oil level Result: The transmission oil level is OK.

A. Check the oil level of the transmission. Proceed to Test Step 2.

Result: The transmission oil level is NOT OK.

Repair: Remove the excess oil. Locate the source of the

extra oil and make the necessary repairs.

If the problem is not resolved, proceed to Test Step 2.

2. Transmission Oil Cooler Oil cooler Result: The coolant temperature is OK.

A. Check for high coolant temperature. Return to service.

Result: The coolant temperature is NOT OK.

Repair: Refer to Troubleshooting, “Coolant Temperature

is High”.

If the procedure did not correct the issue, contact the

Dealer Solutions Network (DSN).

i06026810

Valve Lash Is Excessive

Probable Causes
• Lubrication
• Valve train components

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

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 M0095947-10 205
Symptom Troubleshooting

Table 128
Troubleshooting Test Steps Values Results

1. Lubrication Lubrication Result: The oil flow to the valve mechanism is insufficient.

A. Remove the valve mechanism cover. Refer to Disassem- Repair: Make sure that the passages for the engine oil are
bly and Assembly, “Valve Mechanism Cover - Remove and clear.
Install” for the correct procedure.
Result: The oil flow to the valve mechanism is OK.
B. Crank the engine and check the lubrication in the valve
compartment. Ensure that there is adequate engine oil flow in Proceed to Test Step 2.
the valve compartment. The passages for the engine oil must
be clean.

Note: Do not run the engine with the valve mechanism cover
removed.

2. Valve Train Components Valve train Result: A valve train component is worn, bent, or not clean.
components
A. Inspect the following components of the valve train for ab- Repair: Repair or replace the component. Refer to Disassem-
normal or excessive wear, straightness, and cleanliness: bly and Assembly.

· Rocker arms Note: If the camshaft is replaced, new valve lifters must also
· Valve bridges be installed.
· Pushrods
· Hydraulic lifters Result: All the valve train components are OK.
· Camshaft
· Valve stems Contact the Dealer Solutions Network (DSN).
· Rocker shafts

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 206 M0095947-10
Circuit Tests

Circuit Tests

i07979137

CAN Data Link - Test

Use this procedure if a fault is suspected in the CAN

data links. Also, use this procedure if one of the
following diagnostic codes is active:
Table 129
Diagnostic Trouble Codes for the CAN Data Link Circuit

J1939
Code Code Description Comments
639-9 J1939 Network #1 : Abnormal Update Rate Another controller has incorrectly stopped transmitting an expected J1939
message or another controller has incorrectly started transmitting a conflict-
ing J1939 message.
This diagnostic code applies to the CAN A datalink.
The ECM will log the diagnostic code.
The engine will not start.

1235-9 J1939 Network #3 : Abnormal Update Rate One of the following components has incorrectly stopped or started trans-
mitting a data request:
• NOx sensors
• Diesel Exhaust Fluid (DEF) Tank Header Unit
• Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), or Selec-
tive Catalytic Reduction (SCR) inlet temperature sensor
This diagnostic code applies to the CAN C datalink.
The ECM will log the diagnostic code.

The following background information is related

to this procedure:
The CAN data links are also known as J1939 data
links. A data link is an industry standard for sending
data between different devices in the same
application.
High-speed data is transferred via the data links. The
data links cannot be accurately tested without
complicated equipment. The data links require a
resistance of 60 Ohms between the two wires to
transmit the data correctly. This resistance is made
up of two 120 Ohm resistors. The two resistors are
known as “Terminating Resistors” . The terminating
resistors should be at opposite ends of a data link
circuit. If this resistance is not present, then the data
will be intermittent or unreadable.
Note: The wiring for a J1939 data link is a shielded
twisted-pair cable. If the wiring is damaged, the
replacement type must be shielded twisted-pair
cable.

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 M0095947-10 207
Circuit Tests

Illustration 25 g06497597
Typical example of the schematic for the CAN A data link

Illustration 26 g06327401
Typical example of the schematic for the CAN C data link

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 208 M0095947-10
Circuit Tests

Table 130
Troubleshooting Test Steps Values Results

1. Use the “ System Communication Status to Check the Sta- Component Result: A 639-9 diagnostic code is active or logged.
tus of the Other Devices on the Suspect CAN Data Link”” Identified
Repair: Perform a full power-down of the application. Allow
A. In the electronic service tool, click the “Diagnostics” tab on the time for the DEF system to purge before turning the battery
tool bar. isolator to the OFF position.

B. Select the “System Communication Status” option from the Once the application is fully powered down, reapply power
drop-down list. to the application. The 639-9 code will be reset.

Result: One or more of the devices on the suspect data link

is not visible on the electronic service tool.

Repair: Thoroughly inspect the electrical connectors for the

suspect devices
Refer to Troubleshooting, “Electrical Connectors - Inspect”.
Check the power supply to the suspect devices.
If necessary, refer to Troubleshooting, “Electrical Power
Supply - Test”.

If the fault has been resolved, return the engine to service.

If the fault is still present, proceed to Test Step 2.

Result: All devices are visible on the electronic service tool.

Proceed to Test Step 2.

2. Check the Data Link Terminating Resistance Between 50 Result: The resistance is less than 50 Ohms - there is a
Ohms and 70 short circuit in the harness.
A. Disconnect the P1 connector and the P2 connector from the Ohms
ECM. Repair: Repair the connectors or the harness and/or replace
the connectors or the harness. Ensure that all the seals are
B. Measure the resistance between P1:48 and P1:59. Measure correctly in place and ensure that the connectors are cor-
the resistance between P2:102 and P2:80. rectly connected.
Use the electronic service tool to clear all logged diagnostic
codes and then verify that the repair eliminates the fault.

Result: The resistance is between 110 and 130 Ohms - one

of the terminating resistors may have failed.

Repair: Locate the two terminating resistors and remove the

two terminating resistors from the harness. Depending on
the application, one or both of the terminating resistors may
be located in other ECMs on the data link.
Measure the resistance of the two terminating resistors.
If one of the terminating resistors is incorrect, replace the
faulty terminating resistor.
If the two terminating resistors are between 110 and 130
Ohms, proceed to Test Step 4.

Result: The resistance is greater than 150 Ohms.

Proceed to Test Step 3.

Result: The resistance is between 50 and 70 Ohms

The resistance is correct. The fault may be in the connection

to other devices on the data link.
Proceed to Test Step 3.

(continued)

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 M0095947-10 209
Circuit Tests

(Table 130, contd)

Troubleshooting Test Steps Values Results

3. Check the Data Link Wiring Less than 2 Result: At least one of the resistance measurements is
Ohms greater than 2 Ohms - there is an open circuit or high resist-
A. Disconnect each of the connectors that connect other devices ance in the wiring.
on the data link.
Repair: Repair the connectors or the harness and/or replace
B. Use a multimeter to measure the resistance between P1:48 the connectors or the harness.
and each of the CAN+ pins on other devices on the CAN A data Ensure that all seals are correctly in place and ensure that
link. the connectors are correctly connected.

C. Use a multimeter to measure the resistance between P1:48 Use the electronic service tool to clear all logged diagnostic
and pin (G) on the diagnostic connector. codes and then verify that the repair has eliminated the fault.

D. Use a multimeter to measure the resistance between P1:59 Result: All measured resistances are less than 2 Ohms.
and each of the CAN- pins on other devices on the CAN A data
link. Proceed to Test Step 4.

E. Use a multimeter to measure the resistance between P1:59

and pin (F) on the diagnostic connector.

F. Use a multimeter to measure the resistance between P2:80 to

each of the CAN+ pins on other devices on the CAN C data link.

G. Use a multimeter to measure the resistance between P2:102 to

each of the CAN- pins on other devices on the CAN C data link.

4. Check the Other Devices on the CAN Data Link Other devi- Result: At least one of the other devices is not operating
ces are OK correctly.
A. Use the appropriate service tools to diagnose other devices on
the data link. Repair: Use the appropriate service tools to repair other de-
vices on the data link.

Use the electronic service tool to clear all logged diagnostic

codes and then verify that the repair eliminates the fault.

Result: The other devices are operating correctly.

Contact the Dealer Solutions Network (DSN).

i08125421

Coolant Diverter - Test

This procedure covers the following diagnostic

codes:

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 210 M0095947-10
Circuit Tests

Table 131
Diagnostic Codes for the Coolant Diverter Valve

J1939 Code Code Description Comments

The ECM detects the following conditions:

A low current condition in the output from the solenoid in the coolant diverter valve to the
Aftertreatment #1 DEF Tank Heater Electronic Control Module (ECM).
3363-5
: Current Below Normal
There are no active 168 diagnostic codes.

The warning lamp will come on. The diagnostic code will be logged.

The ECM detects the following conditions:

A high current condition in the output from the solenoid in the coolant diverter valve to
Aftertreatment #1 DEF Tank Heater the ECM.
3363-6
: Current Above Normal
There are no active 168 diagnostic codes.

The warning lamp will come on. The diagnostic code will be logged.

Follow the troubleshooting procedure to identify the root cause of the fault.

The following background information is related

to this procedure:
Coolant Diverter Valve
The coolant diverter valve controls the flow of coolant
to the heater in the Diesel Exhaust Fluid (DEF) pump
and the DEF tank. When required, the valve is
opened to allow hot coolant to circulate through the
DEF pump and the DEF tank. This flow allows the
coolant to heat the DEF to a useable temperature.
DEF Coolant Diverter Valve Solenoid Override
The override is used to check the solenoid and
diverter valve harness. This override will open the
coolant diverter valve, allowing coolant to flow
through the DEF pump and the DEF tank. This test
can be used to verify that the coolant diverter valve is
working correctly.
This override will only enable with the engine running
at idle prior to the DEF system priming to operating
pressure.

Illustration 27 g06370226
Schematic diagram for the coolant diverter valve

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 M0095947-10 211
Circuit Tests

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the coolant diverter valve
connector and the ECM connectors.
Table 132
Troubleshooting Test Steps Values Results
At least 12.5 V for a
1. Check the Battery Voltage 12 V system Result: The battery voltage is lower than the expected
At least 25V for a range.
A. Turn the keyswitch to the OFF position. 24V system
Repair: Refer to Troubleshooting, Battery Problem to in-
B. Use a suitable multimeter to measure the battery voltage. vestigate the cause of low battery voltage.

Result: The battery voltage is within the expected

range.

Proceed to Test Step 2.

At least 12.5 V for a

2. Check the Voltage at the Coolant Diverter Valve 12 V system Result: The voltage is lower than the expected range.
Connector At least 25V for a There is a fault in the wiring between the coolant diverter
24V system valve and the SCR main relay.
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the coolant diverter valve. Repair: Repair the faulty wiring or replace the faulty
wiring.
C. Turn the keyswitch to the ON position.
Result: The voltage is within the expected range.
D. Use a suitable multimeter to measure the voltage between
terminal 1 on the harness connector for the coolant diverter Proceed to Test Step 3.
valve and a suitable ground.

E. Turn the keyswitch to the OFF position.

3. Inspect Electrical Connectors and Wiring Loose connection or Result: There is a fault in a connector or the wiring.
damaged wire
A. Thoroughly inspect the connector for the coolant diverter Repair: Repair any faulty connectors or replace the wir-
valve. Refer to Troubleshooting, “Electrical Connectors - In- ing harness. Ensure that all the seals are properly in
spect” for details. place and ensure that the connectors are correctly
coupled.
B. Thoroughly inspect any connectors between the coolant
diverter valve and the ECM. Refer to Troubleshooting, “Electri- Use the electronic service tool to clear all logged diag-
cal Connectors - Inspect” for details. nostic codes.
Use the electronic service tool to perform the “DEF Cool-
C. Check the harness for corrosion, abrasion, and pinch points ant Diverter Valve Solenoid Override” to verify that the
from the coolant diverter valve to the ECM. repair eliminates the fault.

Note: Do not disconnect the ECM connector at this stage. The Result: All connectors, pins, and sockets are correctly
ECM can only be disconnected and reconnected 10 times be- coupled and/or inserted. The harness is free of corro-
fore damage to the harness connector may occur. sion, abrasion, and pinch points.

Proceed to Test Step 4.

(continued)

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 212 M0095947-10
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(Table 132, contd)

Troubleshooting Test Steps Values Results

4. Check for Active Diagnostic Codes Diagnostic codes Result: A 3363–5 diagnostic code is active.

A. Turn the keyswitch to the OFF position. Proceed to Test Step 5.

B. Connect the electronic service tool to the diagnostic Result: A 3363–6 diagnostic code is active.
connector.
Proceed to Test Step 8.
C. Turn the keyswitch to the ON position.
Result: No diagnostic codes are active. There may be
D. Start the engine. an intermittent fault.

E. Use the electronic service tool to perform the “DEF Coolant Repair: Use the electronic service tool to perform a Wig-
Diverter Valve Solenoid Override” . gle Test.

F. Verify if any of the diagnostic codes that are listed in Table If no faults are found, return the unit to service.
131 are active.
If the Wiggle Test identifies a fault, investigate the cause.
G. Turn the keyswitch to the OFF position.

5. Create a Short Circuit at the Harness Connector for the Short circuit Result: A 3363-5 diagnostic code was active before in-
Coolant Diverter Valve stalling the jumper. A 3363-6 diagnostic code is active
when the jumper is installed - There is a fault in the cool-
A. Turn the keyswitch to the OFF position. ant diverter valve.

B. Disconnect the connector for the coolant diverter valve. Repair: Install a replacement coolant diverter valve.

C. Fabricate a jumper wire that is 150 mm (6 inch) long. Use the electronic service tool to perform the “DEF Cool-
ant Diverter Valve Solenoid Override” to check that the
D. Install the wire between the terminal 1 and terminal 4 on repair eliminates the fault.
the harness connector for the coolant diverter valve to create
a short circuit. Result: A 3363-5 diagnostic code is still active with the
jumper installed.
E. Turn the keyswitch to the ON position. Use the electronic
service tool to perform the “DEF Coolant Diverter Valve Sole- Remove the jumper. Reconnect all connectors. Proceed
noid Override” . to Test Step 6.

F. Check for active diagnostic codes.

G. Remove the jumper wire from the connector for the coolant
diverter valve.

(continued)

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 M0095947-10 213
Circuit Tests

(Table 132, contd)

Troubleshooting Test Steps Values Results

6. Check the Wiring Between the Coolant Diverter Valve Less than 2 Ohms Result: The resistance is greater than 2 Ohms - There
and the Interface Connector (if equipped) for an Open is a fault in the wiring between the coolant diverter valve
Circuit connector and the interface connector.

Note: This step is only applicable if an interface connector is Repair: Repair the faulty wiring or replace the faulty
installed between the coolant diverter valve and the ECM. Re- wiring.
fer to the Electrical Schematic for the application for more in-
formation. Proceed to Test Step 7 if no interface connector is Use the electronic service tool to perform the “DEF Cool-
installed. ant Diverter Valve Solenoid Override” to check that the
repair eliminates the fault.
A. Turn the keyswitch to the OFF position.
Result: The measured resistance is less than 2 Ohms.
B. Disconnect the connector for the coolant diverter valve.
Disconnect the interface connector between the coolant Reconnect all connectors. Proceed to Test Step 7.
diverter valve and the ECM.

C. Use a suitable multimeter to measure the resistance be-

tween terminal 4 on the harness connector for the coolant
diverter valve and the appropriate pin/terminal on the interface
connector.

7. Check the Wiring to the ECM for an Open Circuit Less than 2 Ohms Result: The resistance is greater than 2 Ohms. The fault
is in the wiring connected to the ECM connector.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty
B. Disconnect the P1 connector. Disconnect the connector for wiring.
the coolant diverter valve.
Result: The resistance is less than 2 Ohms.
C. Inspect the P1/J1 connectors for damage or corrosion. Re-
fer to Troubleshooting, Electrical Connectors - Inspect for Contact the Dealer Solutions Network (DSN).
more information.

D. Perform a 30 N (6.7 lb) pull test on P1:82 and P1:83.

E. Use a suitable multimeter to measure the resistance be-

tween terminal 4 on the harness connector for the coolant
diverter valve and P1:82. Repeat the process between termi-
nal 4 on the harness connector for the coolant diverter valve
and P1:83

8. Create an Open Circuit at the Coolant Diverter Valve Open circuit Result: A 3363-6 diagnostic code was active before dis-
connecting the coolant diverter valve. A 3363-5 diagnos-
A. Turn the keyswitch to the OFF position. tic code is active with the coolant diverter valve
disconnected. The fault is in the coolant diverter valve.
B. Disconnect the connector for the coolant diverter valve.
Repair: Install a replacement coolant diverter valve.
C. Turn the keyswitch to the ON position. Use the electronic Use the electronic service tool to perform the “DEF Cool-
service tool to perform the “DEF Coolant Diverter Valve Sole- ant Diverter Valve Solenoid Override” to check that the
noid Override” . repair eliminates the fault.

D. Check for active diagnostic codes. Result: A 3363-6 diagnostic code is still active with the
coolant diverter valve disconnected.

Proceed to Test Step 9.

(continued)

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 214 M0095947-10
Circuit Tests

(Table 132, contd)

Troubleshooting Test Steps Values Results

9. Check the Wiring Between the Coolant Diverter Valve Greater than 1 k Result: At least one of the resistance measurements is
and the Interface Connector (if equipped) for a Short Ohm less than 1 k Ohm. There is a fault in the wiring between
Circuit the coolant diverter valve connector and the interface
connector.
Note: This step is only applicable if an interface connector is
installed between the coolant diverter valve and the ECM. Re- Repair: Repair the faulty wiring or replace the faulty
fer to the Electrical Schematic for the application for more in- wiring.
formation. Proceed to Test Step 10 if no interface connector is
installed. Use the electronic service tool to perform the “DEF Cool-
ant Diverter Valve Solenoid Override” to check that the
A. Turn the keyswitch to the OFF position. repair eliminates the fault.

B. Disconnect the connector for the coolant diverter valve. Result: All measured resistances are greater than 1 k
Disconnect the interface connector between the coolant Ohm.
diverter valve and the ECM.
Reconnect all connectors. Proceed to Test Step 10.
C. Use a suitable multimeter to measure the resistance be-
tween the coolant diverter valve return terminal on the inter-
face connector and all other terminals on the interface
connector.

10. Check the Wiring to the ECM for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is
Ohm less than 1 k Ohm. The fault is in the wiring connected to
A. Turn the keyswitch to the OFF position. the ECM connector.

B. Disconnect the P1 connector. Disconnect the connector for Repair: Repair the faulty wiring or replace the faulty
the coolant diverter valve. wiring.

C. Inspect the P1/J1 connectors for damage or corrosion. Re- Result: All resistance measurements are greater than 1
fer to Troubleshooting, Electrical Connectors - Inspect for k Ohm.
more information.
Contact the Dealer Solutions Network (DSN).
D. Perform a 30 N (6.7 lb) pull test on the wire in the P1:82.

E. Use a suitable multimeter to measure the resistance be-

tween P1:82 and all other terminals on the P1 connector.

i08068424

Cooling Fan Control - Test

Use this procedure to troubleshoot the electrical

system if a problem is suspected with the engine fan
control solenoids. Use this procedure if one of the
diagnostic codes in Table 133 is active.

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 M0095947-10 215
Circuit Tests

Table 133
Diagnostic Trouble Codes for the Cooling Fan Solenoid

J1939
Code Description Notes
Fan Drive State : Current Be- The Electronic Control Module (ECM) detects the following conditions:
977–5
low Normal
A low current condition in the output from the ECM to the cooling fan solenoid.

Fan Drive Bypass Command There are no active 168 diagnostic codes.
4212–5 Status: Current Below
Normal The Alert lamp will come on. The ECM will log the diagnostic code.
This diagnostic code will detect a fault in the circuit for the cooling fan solenoid that is most likely to be
an open circuit.

Fan Drive State : Current The ECM detects the following conditions:
977–6
Above Normal
A high current condition in the output from the ECM to the cooling fan solenoid.

Fan Drive Bypass Command There are no active 168 diagnostic codes.
4212–6 Status: Current Above
Normal The Alert lamp will come on. The ECM will log the diagnostic code.
This diagnostic code will detect a fault in the circuit for the cooling fan solenoid. This problem is most
likely to be caused by a high side short to ground or a low side short to power.

Refer to the Electrical Schematic for the application.

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Table 134
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Electrical Result: All connectors, pins, and sockets are correctly
connectors connected and the harness is free of corrosion, abra-
A. Thoroughly inspect the P2/J2 ECM connectors and thoroughly in- sion, and pinch points.
spect the connector for the fan drive assembly. Refer to Trouble-
shooting, “Electrical Connectors - Inspect” for details. Proceed to Test Step 2.

B. Perform a 30 N (6.7 lb) pull test on each of the wires that are as- Result: There is a fault in the connectors and/or the
sociated with the fan drive assembly. harness.

Repair: Repair the connectors or the harness and/or re-

place the connectors or the harness. Ensure that all the
seals are correctly in place and ensure that the connec-
tors are correctly connected.

Use the electronic service tool to clear all logged diag-

nostic codes and then verify that the repair eliminates
the fault.

2. Check for Active Diagnostic Codes Active Diagnos- Result: No diagnostic codes are active.
tic Codes
A. Remove the electrical power from the ECM. The problem may have been related to a faulty connec-
tion in the harness. Carefully inspect the connectors
B. Verify that the solenoid connectors are free of debris and con- and wiring. Refer to Troubleshooting, “Electrical Con-
nected securely. nectors - Inspect”.

C. Connect the electronic service tool to the diagnostic connector. Result: A 977–5 or 4212-5 code is active.

D. Restore the electrical power to the ECM. Proceed to Test Step 3.

E. Select diagnostic tests on the electronic service tool. Result: A 977–6 or 4212–6 code is active.

F. Select the “Override Parameters” screen. Proceed to Test Step 4.

G. Activate the fan override.

H. Monitor the active diagnostic code screen on the electronic serv-

ice tool. Check and record any active diagnostic codes. Wait at least
30 seconds in order for the diagnostic code to become active.

I. Disable the fan override.

(continued)

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 M0095947-10 217
Circuit Tests

(Table 134, contd)

Troubleshooting Test Steps Values Results

3. Create a Short Circuit in the Harness at the Solenoid Short Circuit Result: The 977–5 or 4212–5 code remains active with
the jumper in place.
A. Turn the keyswitch to the OFF position.
Proceed to Test Step 5.
B. Disconnect the connector for the fan drive assembly.
Result: A 977–6 or 4212–6 code is active when the
C. Fabricate a jumper wire that is long enough to create a short be- jumper wire is installed. A 977–5 or 4212–5 code is ac-
tween the terminals of the connector for the fan drive assembly. tive when the jumper wire is removed.
Crimp connector pins to each end of the jumper wire.
Repair: Replace the fan drive assembly. Reset all active
D. Install the wire between the fan control terminal and the fan con- codes and clear all logged codes. Verify that the fault is
trol return terminal on the harness connector for the fan drive assem- resolved.
bly to create a short circuit.
If the fault is still present, contact the Dealer Solutions
E. Turn the keyswitch to the ON position. Wait for 10 seconds. Check Network (DSN).
for active diagnostic codes on the electronic service tool.

E. Activate the fan override.

F. Monitor the active diagnostic code screen on the electronic serv-

ice tool. Check and record any active diagnostic codes. Wait at least
30 seconds in order for the diagnostic code to become active.

Disable the fan override. Remove the jumper wire.

4. Create an Open Circuit at the Solenoid Open circuit Result: A 977–6 or 4212–6 code was active before dis-
connecting the connector. A 977–5 or 4212–5 code be-
A. Turn the keyswitch to the OFF position. came active after disconnecting the connector.

B. Disconnect the connector for the fan drive assembly. Repair: Replace the fan drive assembly. Reset all active
codes and clear all logged codes. Verify that the fault is
C. Turn the keyswitch to the ON position. Wait for 10 seconds. resolved.
Check for active diagnostic codes on the electronic service tool.
If the fault is still present, contact the Dealer Solutions
D. Activate the fan override. Network (DSN).

E. Monitor the active diagnostic code screen on the electronic serv- Result: A 977–6 or 4212–6 code remains active. There
ice tool. Check and record any active diagnostic codes. Wait at least is a short circuit between the harness connector for the
30 seconds in order for the diagnostic code to become active. engine fan control solenoid and the ECM.

F. Disable the fan override. Proceed to Test Step 5.

5. Bypass the Wiring Harness Wiring bypass Result: The diagnostic code disappears when the jump-
er is installed. There is a fault in the wiring harness be-
A. Turn the keyswitch to the OFF position. tween the ECM and the cooling fan solenoid connector.

B. Disconnect the P2 connector and the fan drive assembly Repair: Repair the connectors or wiring and/or replace
connector. the connectors or wiring. Reset all active codes and
clear all logged codes. Verify that the fault is resolved.
C. Remove the wires for the solenoid control and solenoid return
from the P2 connector. Refer to the electrical schematic for the If the fault is still present, contact the Dealer Solutions
application. Network (DSN).

D. Remove the control and return wires from the connector for the Result: The diagnostic code is still present with the
fan drive assembly. jumper installed

Contact the Dealer Solutions Network (DSN).

(continued)

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(Table 134, contd)

Troubleshooting Test Steps Values Results
E. Fabricate two jumper wires that are long enough to reach from
the ECM to the fan drive assembly connector.

F. Insert one end of a jumper into the solenoid control position on the
P2 connector. Insert the other end of the jumper into socket 4 on the
harness connector for the fan drive assembly.

G. Insert one end of a jumper into the solenoid return position on the
P2 connector. Insert the other end of the jumper into socket 3 on the
harness connector for the fan drive assembly.

H. Reconnect the P1 connector and the fan drive assembly

connector.

I. Turn the keyswitch to the ON position. Wait for 10 seconds.

J. Use the electronic service tool to monitor the “Active Diagnostic

Code” screen. Check for a diagnostic code.

K. Remove the jumpers and reconnect the wires that were previ-
ously removed. Reconnect the connectors.

i07708957

Cooling Fan Speed - Test

Use this procedure to troubleshoot the electrical

system if a problem is suspected with the cooling fan
speed sensor. Also use this procedure if the
diagnostic code in Table 135 is active or easily
repeated.
Table 135
Diagnostic Code Table for Cooling Fan Speed
J1939 Code Code Description Comments

1639-17 Fan Speed : Low - least severe (1) The code is logged.

The engine cooling fan speed sensor provides a Complete the procedure in the order in which the
signal to the Electronic Control Module (ECM). The steps are listed.
ECM controls fan speed by varying the current to the
fan control solenoid.
The engine cooling fan speed sensor receives a
supply voltage from the ECM. The sensor outputs a
frequency that is directly proportional to fan speed.
During the following procedure, refer to the electrical
schematic for the application.
Table 136
Required Tools

Tool Part Number Part Description Qty

A - Tachometer Kit 1

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 M0095947-10 219
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Table 137
Troubleshooting Test Steps Values Results

1. Check the Status of the Engine Fan Speed Fan Speed Result: The engine fan speed is within ± 50 rpm.

A. Turn the keyswitch to the OFF position. The sensor is operating correctly. There may be an intermit-
tent electrical problem in a connector or in the harness. If an
B. Connect the electronic service tool to the diagnostic intermittent problem is suspected, refer to Troubleshooting,
connector. “Electrical Connectors - Inspect”.

C. Turn the keyswitch to the ON position. Result: The engine fan speed is not within ± 50 rpm.

D. Access the “Fan Override Test” under the “Diagnostics” Proceed to Test Step 2.
menu.

E. Start the “Fan Override Test” on the electronic service tool.

Set the fan speed to 500 rpm.

F. Use Tooling (A) to determine the actual speed of the fan.

G. Compare the engine fan speed that is reported by the elec-

tronic service tool to the actual engine fan speed that is re-
ported by Tooling (A).

H. Deactivate the “Fan Override Test” .

I. Turn the keyswitch to the OFF position.

(continued)

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 220 M0095947-10
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(Table 137, contd)

2. Check the Sensor Supply Voltage at the Sensor Supply Voltage Result: The supply voltage is not reaching the sensor.
Connector
Repair: Refer to Troubleshooting, “Sensor Supply - Test”.
A. Turn the keyswitch to the OFF position.
Result: The supply voltage is reaching the sensor.
B. Disconnect the sensor connector from the wiring harness.
Proceed to Test Step 3.
C. Turn the keyswitch to the ON position.

D. Measure the sensor supply voltage between terminal 2 and

terminal 3.

3. Check the Signal Frequency at the Sensor Connector Sensor Result: The frequency is approximately 80 Hz.
Frequency
A. Turn the keyswitch to the OFF position. The engine cooling fan speed sensor is generating the correct
signal.
B. Remove the wire from terminal 1 on the sensor side of the
connector. Connect the sensor connector. Repair: Repair the harness or replace the harness.

C. Turn the keyswitch to the ON position. Verify that the fault is resolved.

D. Access the “Fan Override Test” under the “Diagnostics” Result: The frequency is not approximately 80 Hz.
menu on the electronic service tool.
Repair: Replace the fan speed sensor.
E. Start the “Fan Override Test” on the electronic service tool.
Set the fan speed to 800 rpm. Verify that the fault is resolved.

F. Use a multimeter to measure the frequency between the If the fault is still present, contact the Dealer Solutions Net-
signal wire from the sensor and engine ground. work (DSN).

G. Deactivate the “Fan Override Test” .

H. Turn the keyswitch to the OFF position.

I. Restore all connectors and wiring to the original

configuration.

i08362004

Data Link Configuration Status

- Test

Use this procedure if one of the following diagnostic

codes are active.
Note: Some of the following codes may not be
applicable for certain applications.

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 M0095947-10 221
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Table 138
Diagnostic Trouble Codes for the Data Link Configuration Status

J1939 Code Code Description Comments

The data received from the CAN A data bus is not in the
639-14 J1939 Network #1 : Special Instruction correct format.
The code is logged.

The data received from the CAN C data bus is not in the
1231–14 J1939 Network 2: Special Instruction correct format.
The code is logged.

Complete the procedure in the order in which the

steps are listed.
Table 139
Troubleshooting Test Steps Values Results

1. Check for an Associated -9 Code Associated Trou- Result: An associated -9 code is logged.
ble code
A. Establish communication between the electronic service tool Repair: Repair all associated -9 codes before continuing
and the Electronic Control Module (ECM) for the engine. with this procedure. Refer to Troubleshooting, “CAN Da-
ta Link - Test”.
B. Check for active diagnostic codes.
If a -14 code is still present after resolving the -9 code,
proceed to Test Step 2.

Result: An associated -9 code is not logged.

Proceed to Test Step 2.

2. Check the Personality Module Code for Compatibility with Compatible per- Result: The code is valid for the application.
the Application sonality module
Proceed to Test Step 3.
A. Connect to the electronic service tool.
Result: The code is not valid for the application.
B. Select the ECM connection that is related to the logged code.
Repair: Obtain the correct flash file and update the
C. Check if the personality module code is valid for the application. ECM. Reset all active codes and clear all logged codes.
Return the unit to service.

3. Check that the Latest Available Software is Installed Software Result: The latest software is not installed.

Repair: Install the latest software. If necessary, refer to

A. Ensure that the latest software is installed on the engine ECM . Troubleshooting, “ECM Software - Install” for the correct
Ensure that the software installed is for the correct system voltage procedure.
(12 V or 24 V). Turn the keyswitch to the on position.
If necessary, refer to Troubleshooting, “ECM Software - Install” for If the fault is cleared, return the engine to service.
the correct procedure. If the fault is still present, proceed to Test Step 4.

Result: The latest software is installed. The software is

for the correct system voltage.

Proceed to Test Step 4.

(continued)

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 222 M0095947-10
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(Table 139, contd)

Troubleshooting Test Steps Values Results

4. Check the Configuration Parameters Correct configu- Result: The configuration parameters are programmed
ration correctly.
A. Check the configuration parameters to ensure that the parame- parameters
ters are programmed correctly. Refer to Troubleshooting, “Configu- Proceed to Test Step 5.
ration Parameters”.
Result: The configuration parameters are not pro-
B. Select the ECM connection that is related to the logged code. grammed correctly.

Repair: Program the parameters to function with the oth-

er modules on the data link. Reset all active codes and
clear all logged codes. Return the unit to service.

5. Check for Compatibility with Any Other ECM on the Data Compatible Result: The ECMs are not compatible.
Link ECM
Repair:Replace the incompatible ECM with the correct
A. Determine if any other ECM or display on the data link are module. Reset all active codes and clear all logged co-
incompatible. des. Return the unit to service.

B. Select the ECM connection that is related to the logged code. If the procedure did not correct the fault, contact the
Dealer Solutions Network (DSN).

i07585315

DEF Injector - Test

This procedure covers the following diagnostic

codes:
Table 140
Diagnostic Codes for the Diesel Exhaust Fluid (DEF) Injector

J1939 Code Code Description Comments

The ECM detects the following conditions:

A low current condition in the output from the solenoid in the DEF injector to the Elec-
Aftertreatment #1 DEF Dosing Unit tronic Control Module (ECM).
3361-5
: Current Below Normal
There are no active 168 diagnostic codes.

The warning lamp will come on. The diagnostic code will be logged.

The ECM detects the following conditions:

A high current condition in the output from the solenoid in the DEF injector to the ECM.
Aftertreatment #1 DEF Dosing Unit
3361-6
: Current Above Normal
There are no active 168 diagnostic codes.

The warning lamp will come on. The diagnostic code will be logged.

Follow the troubleshooting procedure to identify the root cause of the fault.

The following background information is related The DEF injector controls the flow of DEF into the
to this procedure: exhaust stream. The DEF injector is controlled by the
ECM.
DEF Injector
DEF Dosing Injector Override

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Circuit Tests

This override allows the user to test the electrical

circuit for the DEF injector. The override commands
the DEF injector to open. This override only operates
when there is no engine speed.

Illustration 28 g06370898
Schematic diagram for the DEF injector

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the DEF injector connector
and the ECM connectors.

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 224 M0095947-10
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Table 141
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection or Result: There is a fault in a connector or the wiring.
damaged wire
A. Thoroughly inspect the connector for the DEF injector. Re- Repair: Repair any faulty connectors or replace the wir-
fer to Troubleshooting, “Electrical Connectors - Inspect” for ing harness. Ensure that all the seals are properly in
details. place and ensure that the connectors are correctly
coupled.
B. Thoroughly inspect any connectors between the DEF injec-
tor and the ECM. Refer to Troubleshooting, “Electrical Con- Use the electronic service tool to clear all logged diag-
nectors - Inspect” for details. nostic codes.
Use the electronic service tool to perform the “DEF Dos-
C. Check the harness for corrosion, abrasion, and pinch points ing Injector Override” to verify that the repair eliminates
from the DEF Injector to the ECM. the fault.

Note: Do not disconnect the ECM connector at this stage. The Result: All connectors, pins, and sockets are correctly
ECM can only be disconnected and reconnected 10 times be- coupled and/or inserted. The harness is free of corro-
fore damage to the harness connector may occur. sion, abrasion, and pinch points.

Proceed to Test Step 2.

2. Check for Active Diagnostic Codes Diagnostic codes Result: A 3361–5 diagnostic code is active.

A. Turn the keyswitch to the OFF position. Proceed to Test Step 3.

B. Connect the electronic service tool to the diagnostic Result: A 3361–6 diagnostic code is active.
connector.
Proceed to Test Step 6.
C. Turn the keyswitch to the ON position.
Result: No diagnostic codes are active. There may be
D. Use the electronic service tool to perform the “DEF Dosing an intermittent fault.
Injector Override” .
Repair: Use the electronic service tool to perform a Wig-
E. Verify if any of the diagnostic codes that are listed in Table gle Test.
140 are active.
If no faults are found, return the unit to service.
F. Turn the keyswitch to the OFF position.
If the Wiggle Test identifies a fault, investigate the cause.

(continued)

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 M0095947-10 225
Circuit Tests

(Table 141, contd)

Troubleshooting Test Steps Values Results

3. Create a Short Circuit at the Harness Connector for the Short circuit Result: A 3361-5 diagnostic code was active before in-
DEF Injector stalling the jumper. A 3361-6 diagnostic code is active
when the jumper is installed - There is a fault in the DEF
A. Turn the keyswitch to the OFF position. injector.

B. Disconnect the connector for the DEF injector. Repair: Install a replacement DEF injector. Refer to Dis-
assembly and Assembly, DEF Injector and Mounting -
C. Fabricate a jumper wire that is 150 mm (6 inch) long. Remove and Install.

D. Install the wire between the terminal 1 and terminal 2 on Use the electronic service tool to perform the “DEF Dos-
the harness connector for the DEF injector to create a short ing Injector Override” to check that the repair eliminates
circuit. the fault.

E. Turn the keyswitch to the ON position. Use the electronic Result: A 3361-5 diagnostic code is still active with the
service tool to perform the “DEF Dosing Injector Override” . jumper installed.

F. Check for active diagnostic codes. Remove the jumper. Reconnect all connectors. Proceed
to Test Step 4.
G. Remove the jumper wire from the connector for the DEF
injector.

4. Check the Wiring Between the DEF Injector and the In- Less than 2 Ohms Result: At least one of the measured resistances is
terface Connector (if equipped) for an Open Circuit greater than 2 Ohms. There is a fault in the wiring be-
tween the DEF injector connector and the interface
Note: This step is only applicable if an interface connector is connector.
installed between the DEF injector and the ECM. Refer to the
Electrical Schematic for the application for more information. Repair: Repair the faulty wiring or replace the faulty
Proceed to Test Step 5 if no interface connector is installed. wiring.

A. Turn the keyswitch to the OFF position. Use the electronic service tool to perform the “DEF Dos-
ing Injector Override” to check that the repair eliminates
B. Disconnect the connector for the DEF injector. Disconnect the fault.
the interface connector between the DEF injector and the
ECM. Result: The measured resistance is less than 2 Ohms.

C. Use a suitable multimeter to measure the resistance be- Reconnect all connectors. Proceed to Test Step 5.
tween terminal 1 on the harness connector for the DEF injec-
tor and the appropriate pin/terminal on the interface
connector.
Use a suitable multimeter to measure the resistance between
terminal 2 on the harness connector for the DEF injector and
the appropriate pin/terminal on the interface connector.

(continued)

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(Table 141, contd)

Troubleshooting Test Steps Values Results

5. Check the Wiring to the ECM for an Open Circuit Less than 2 Ohms Result: At least one of the measured resistances is
greater than 2 Ohms. The fault is in the wiring connected
A. Turn the keyswitch to the OFF position. to the ECM connector.

B. Disconnect the P2 connector. Disconnect the connector for Repair: Repair the faulty wiring or replace the faulty
the DEF injector. wiring.

C. Inspect the P2/J2 connectors for damage or corrosion. Re- Result: The resistance is less than 2 Ohms.
fer to Troubleshooting, Electrical Connectors - Inspect for
more information. Contact the Dealer Solutions Network (DSN).

D. Perform a 30 N (6.7 lb) pull test on P2:13 and P2:26.

E. Use a suitable multimeter to measure the resistance be-

tween terminal 1 on the harness connector for the DEF injec-
tor and P2:13.
Use a suitable multimeter to measure the resistance between
terminal 2 on the harness connector for the DEF injector and
P2:26.

6. Create an Open Circuit at the DEF Injector Open circuit Result: A 3361-6 diagnostic code was active before dis-
connecting the DEF injector. A 3361-5 diagnostic code is
A. Turn the keyswitch to the OFF position. active with the DEF injector disconnected. The fault is in
the DEF injector.
B. Disconnect the connector for the DEF injector.
Repair: Install a replacement DEF injector. Refer to Dis-
C. Turn the keyswitch to the ON position. Use the electronic assembly and Assembly, DEF Injector and Mounting -
service tool to perform the “DEF Dosing Injector Override” . Remove and Install.
Use the electronic service tool to perform the “DEF Dos-
D. Check for active diagnostic codes. ing Injector Override” to check that the repair eliminates
the fault.

Result: A 3361-6 diagnostic code is still active with the

DEF injector disconnected.

Proceed to Test Step 7.

(continued)

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 M0095947-10 227
Circuit Tests

(Table 141, contd)

Troubleshooting Test Steps Values Results

7. Check the Wiring Between the DEF Injector and the In- Greater than 1 k Result: At least one of the resistance measurements is
terface Connector (if equipped) for a Short Circuit Ohm less than 1 k Ohm. There is a fault in the wiring between
the DEF injector connector and the interface connector.
Note: This step is only applicable if an interface connector is
installed between the DEF injector and the ECM. Refer to the Repair: Repair the faulty wiring or replace the faulty
Electrical Schematic for the application for more information. wiring.
Proceed to Test Step 8 if no interface connector is installed.
Use the electronic service tool to perform the “DEF Dos-
A. Turn the keyswitch to the OFF position. ing Injector Override” to check that the repair eliminates
the fault.
B. Disconnect the connector for the DEF injector. Disconnect
the interface connector between the DEF injector and the Result: All measured resistances are greater than 1 k
ECM. Ohm.

C. Use a suitable multimeter to measure the resistance be- Reconnect all connectors. Proceed to Test Step 8.
tween the DEF injector return terminal on the interface con-
nector and all other terminals on the interface connector.
Use a suitable multimeter to measure the resistance between
the DEF injector supply terminal on the interface connector
and all other terminals on the interface connector.

8. Check the Wiring to the ECM for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is
Ohm less than 1 k Ohm. The fault is in the wiring connected to
A. Turn the keyswitch to the OFF position. the ECM connector.

B. Disconnect the P2 connector. Disconnect the connector for Repair: Repair the faulty wiring or replace the faulty
the DEF injector. wiring.

C. Inspect the P2/J2 connectors for damage or corrosion. Re- Result: All resistance measurements are greater than 1
fer to Troubleshooting, Electrical Connectors - Inspect for k Ohm.
more information.
Contact the Dealer Solutions Network (DSN).
D. Perform a 30 N (6.7 lb) pull test on the wire in P2:13 and
P2:26.

E. Use a suitable multimeter to measure the resistance be-

tween P2:13 and all other terminals on the P2 connector.
Use a suitable multimeter to measure the resistance between
P2:26 and all other terminals on the P2 connector.

i07451411

DEF Line Heater - Test

The Electronic Control Module (ECM) monitors the

voltage and current flow to the Diesel Exhaust Fluid
(DEF) line heaters.
The engine ECM sets a diagnostic trouble code if the
current flow through a circuit is incorrect. A -5 code
indicates that the current flow through the circuit is
low and there is an open circuit. A -6 code indicates
that the current flow through the circuit is high and
there is a short in the circuit.
Table 142 lists the diagnostic codes for incorrect
current flow.

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 228 M0095947-10
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Table 142
Diagnostic Trouble Codes for DEF Line Heater

J1939 Code Code Description Comments

Aftertreatment #1 DEF Line Heater #1 : This code indicates that there is a fault in the #1 line heater circuit that is probably
4354-5
Current Below Normal an open circuit.

Aftertreatment #1 DEF Line Heater #1 : This code indicates that there is a fault in the #1 line heater circuit that is probably
4354-6
Current Above Normal a short circuit.

Aftertreatment #1 DEF Line Heater #2 : This code indicates that there is a fault in the #2 line heater circuit that is probably
4355-5
Current Below Normal an open circuit.

Aftertreatment #1 DEF Line Heater #2 : This code indicates that there is a fault in the #2 line heater circuit that is probably
4355-6
Current Above Normal a short circuit.

Aftertreatment #1 DEF Line Heater #3 : This code indicates that there is a fault in the #3 line heater circuit that is probably
4356-5
Current Below Normal an open circuit.

Aftertreatment #1 DEF Line Heater #3 : This code indicates that there is a fault in the #3 line heater circuit that is probably
4356-6
Current Above Normal a short circuit.
Follow the troubleshooting procedure to identify the root cause of the fault.

Illustration 29 g06327796
Schematic diagram of the DEF line heater circuit

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the line heater connectors
and the ECM connectors.

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 M0095947-10 229
Circuit Tests

Table 143
Troubleshooting Test Steps Values Results
At least 12.5 V for a
1. Check the Battery Voltage 12 V system Result: The battery voltage is lower than the expected
At least 25V for a range.
A. Turn the keyswitch to the OFF position. 24V system
Repair: Refer to Troubleshooting, Battery Problem to in-
B. Use a suitable multimeter to measure the battery voltage. vestigate the cause of low battery voltage.

Result: The battery voltage is within the expected

range.

Proceed to Test Step 2.

2. Inspect Electrical Connectors and Wiring Loose connection or Result: There is a fault in a connector or the wiring.
damaged wire
A. Thoroughly inspect the connectors for the DEF line heaters. Repair: Repair any faulty connectors or replace the wir-
Refer to Troubleshooting, “Electrical Connectors - Inspect” for ing harness. Ensure that all the seals are properly in
details. place and ensure that the connectors are correctly
coupled.
B. Thoroughly inspect any connectors between the DEF line
heaters and the ECM. Refer to Troubleshooting, “Electrical Use the electronic service tool to clear all logged diag-
Connectors - Inspect” for details. nostic codes and verify that the repair eliminates the
fault.
C. Perform a 45 N (10 lb) pull test on each of the wires in the
DEF line heater connectors and any connectors between the Result: All connectors, pins, and sockets are correctly
DEF line heaters and the ECM. coupled and/or inserted. The harness is free of corro-
sion, abrasion, and pinch points.
D. Check the harness for corrosion, abrasion, and pinch points
from the DEF line heaters to the ECM. Proceed to Test Step 3.

Note: Do not disconnect the ECM connector at this stage. The

ECM can only be disconnected and reconnected 10 times be-
fore damage to the harness connector may occur.

At least 12.5 V for a

3. Check the Supply Voltage to the DEF Line Heaters 12 V system Result: The voltage is not within the expected range.
At least 25V for a
A. Turn the keyswitch to the OFF position. 24V system If the fault is present on all three DEF line heaters, check
the SCR relay for correct operation. Refer to Trouble-
B. Disconnect any suspect DEF line heaters. shooting, Relay - Test (SCR Main Relay).
If the fault is present on one or two of the DEF line heat-
C. Turn the keyswitch to the ON position. ers, the fault is in the wiring between the DEF line heat-
ers and the SCR main relay.
D. Use the electronic service tool to override each DEF line Repair the faulty wiring or replace the faulty wiring.
heater. Use the electronic service tool to override each DEF line
heater to check that the repair eliminates the fault.
E. Use a suitable multimeter to measure the voltage between
terminal 1 of each DEF line heater harness connector and a Result: The voltage is within the expected range.
suitable ground.
Proceed to Test Step 4.

(continued)

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 230 M0095947-10
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(Table 143, contd)

Troubleshooting Test Steps Values Results

4. Check for Active Diagnostic Codes Diagnostic codes Result: A -5 diagnostic code is active.

A. Turn the keyswitch to the OFF position. Proceed to Test Step 5.

B. Connect the electronic service tool to the diagnostic Result: A -6 diagnostic is active.
connector.
Proceed to Test Step 8.
C. Turn the keyswitch to the ON position.

D. Use the electronic service tool to override each DEF line

heater.

E. Verify if any of the diagnostic codes that are listed in Table

142 are active.

F. Turn the keyswitch to the OFF position.

5. Create a Short Circuit at the Harness Connector for the Short circuit Result: A -5 diagnostic code was active before installing
DEF Line Heater the jumper. A -6 diagnostic code is active when the
jumper is installed - There is a fault in the line heater.
A. Turn the keyswitch to the OFF position.
Repair: Install a replacement line heater.
B. Disconnect the connector for the suspect line heater.
Use the electronic service tool to override each DEF line
C. Fabricate a jumper wire that is 150 mm (6 inch) long. heater to check that the repair eliminates the fault.

D. Install the wire between the two pins on the harness con- Result: A -5 diagnostic code is still active with the jump-
nector for the suspect line heater to create a short circuit. er installed.

E. Turn the keyswitch to the ON position. Use the electronic Remove the jumper. Reconnect all connectors. Proceed
service tool to override the suspect line heater. to Test Step 6.

F. Check for active diagnostic codes.

G. Remove the jumper wire from the connector for the line
heater.

(continued)

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 M0095947-10 231
Circuit Tests

(Table 143, contd)

Troubleshooting Test Steps Values Results

6. Check the Wiring Between the DEF Line Heater and the Less than 2 Ohms Result: The resistance is greater than 2 Ohms - There
Interface Connector (if equipped) for an Open Circuit is a fault in the wiring between the DEF line heater con-
nector and the interface connector.
Note: This step is only applicable if an interface connector is
installed between the DEF line heaters and the ECM. Refer to Repair: Repair the faulty wiring or replace the faulty
the Electrical Schematic for the application for more informa- wiring.
tion. Proceed to Test Step 7 if no interface connector is
installed. Use the electronic service tool to override each DEF line
heater to check that the repair eliminates the fault.
A. Turn the keyswitch to the OFF position.
Result: All measured resistances are less than 2 Ohms.
B. Disconnect the connector for the suspect line heater. Dis-
connect the interface connector between the DEF line heaters Reconnect all connectors. Proceed to Test Step 7.
and the ECM.

C. Use a suitable multimeter to measure the resistance be-

tween terminal 2 on the harness connector for the suspect line
heater and the appropriate pin/terminal on the interface
connector.

7. Check the Wiring to the ECM for an Open Circuit Less than 2 Ohms Result: The resistance is greater than 2 Ohms. The fault
is in the wiring connected to the ECM connector.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty
B. Disconnect the P1 or P2 connector. Refer to Illustration 29 wiring.
for the correct connector. Disconnect the connector for the
suspect line heater. Result: The resistance is less than 2 Ohms.

C. Inspect the P1/J1 or P2/J2 connectors for damage or corro- Contact the Dealer Solutions Network (DSN).
sion. Refer to Troubleshooting, Electrical Connectors - Inspect
for more information.

D. Perform a 30 N (6.7 lb) pull test on the wire in the P1/P2

connector that is associated with the active diagnostic code.

E. Use a suitable multimeter to measure the resistance be-

tween terminal 2 on the harness connector for the suspect
DEF line heater and the appropriate terminal on the P1/P2
connector.

8. Create an Open Circuit at the DEF Line Heater Open circuit Result: A -6 diagnostic code was active before discon-
necting the line heater. A -5 diagnostic code is active
A. Turn the keyswitch to the OFF position. with the line heater disconnected. The fault is in the line
heater.
B. Disconnect the connector for the suspect line heater.
Repair: Install a replacement DEF line heater.
C. Turn the keyswitch to the ON position. Use the electronic Use the electronic service tool to override each DEF line
service tool to override the suspect line heater. heater to check that the repair eliminates the fault.

D. Check for active diagnostic codes. Result: A -6 diagnostic code is still active with the line
heater disconnected.

Proceed to Test Step 9.

(continued)

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 232 M0095947-10
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(Table 143, contd)

Troubleshooting Test Steps Values Results

9. Check the Wiring Between the DEF Line Heater and the Greater than 1 k Result: At least one of the resistance measurements is
Interface Connector (if equipped) for a Short Circuit Ohm less than 1 k Ohm. There is a fault in the wiring between
the DEF line heater connector and the interface
Note: This step is only applicable if an interface connector is connector.
installed between the DEF line heaters and the ECM. Refer to
the Electrical Schematic for the application for more informa- Repair: Repair the faulty wiring or replace the faulty
tion. Proceed to Test Step 10 if no interface connector is wiring.
installed.
Use the electronic service tool to override each DEF line
A. Turn the keyswitch to the OFF position. heater to check that the repair eliminates the fault.

B. Disconnect the connector for the suspect line heater. Dis- Result: All measured resistances are greater than 1 k
connect the interface connector between the DEF line heaters Ohm.
and the ECM.
Reconnect all connectors. Proceed to Test Step 10.
C. Use a suitable multimeter to measure the resistance be-
tween the DEF line heater return terminal on the interface con-
nector and all other terminals on the interface connector.

10. Check the Wiring to the ECM for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is
Ohm less than 1 k Ohm. The fault is in the wiring connected to
A. Turn the keyswitch to the OFF position. the ECM connector.

B. Disconnect the P1 or P2 connector. Refer to Illustration 29 Repair: Repair the faulty wiring or replace the faulty
for the correct connector. Disconnect the connector for the wiring.
suspect line heater.
Result: All resistance measurements are greater than 1
C. Inspect the P1/J1 or P2/J2 connectors for damage or corro- k Ohm.
sion. Refer to Troubleshooting, Electrical Connectors - Inspect
for more information. Contact the Dealer Solutions Network (DSN).

D. Perform a 30 N (6.7 lb) pull test on the wire in the P1/P2

connector that is associated with the active diagnostic code.

E. Use a suitable multimeter to measure the resistance be-

tween the DEF line heater return terminal on the P1/P2 con-
nector and all other terminals on the P1/P2 connector.

i08383242 Table 144 lists the diagnostic codes for the DEF
pump motor circuit.
DEF Pump Motor - Test

The Electronic Control Module (ECM) monitors and

controls the Diesel Exhaust Fluid (DEF) pump via
voltages, current, and PWM signals.
The ECM sets a diagnostic trouble code if an error is
detected in one or more of these parameters.
A -5 code indicates that the current flow through the
circuit is low and there is an open in the circuit. A -6
code indicates that the current flow through the circuit
is high and there is a short in the circuit. These codes
can be activated only when the ECM is sending a
command to the DEF pump.

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 M0095947-10 233
Circuit Tests

Table 144
Diagnostic Trouble Codes for the DEF Pump Motor

J1939 Code Code Description Comments

Aftertreatment #1 DEF Pump #1 Motor Speed : Volt- This code indicates that the voltage is above the acceptable range.
4374-3
age Above Normal The code is logged.

Aftertreatment #1 DEF Pump #1 Motor Speed : Volt- This code indicates that the voltage is below the acceptable range.
4374-4
age Below Normal The code is logged.

Aftertreatment #1 DEF Pump #1 Motor Speed : Cur- This code indicates low current to the DEF pump speed sensor.
4374-5
rent Below Normal The code is logged.

Aftertreatment #1 DEF Pump #1 Motor Speed : Cur- This code indicates high current to the DEF pump speed sensor.
4374-6
rent Above Normal The code is logged.

Follow the troubleshooting procedure to identify the root cause of the problem.

Table 145
Required Tools

Tool Part Number Part Description Qty

A T4000242 Break-out Connector 1

Illustration 30 g06650840
Schematic diagram for the DEF pump motor

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the DEF pump connector
and the ECM connectors.

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 234 M0095947-10
Circuit Tests

Illustration 31 g03811015
Pin location on the DEF pump connector
(8) Return
(9) 5V supply
(10) PWM signal

Complete the procedure in the order in which the

steps are listed.
Table 146
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Damaged wire or Result: A damaged wire or damaged connector was not
connector found.
A. Inspect the connector for the DEF pump.
Proceed to Test Step 2.
B. Thoroughly inspect any connectors between the DEF pump
and the ECM. Refer to Troubleshooting, “Electrical Connectors - Result: A damaged wire or damaged connector was
Inspect” for details. found.

C. Perform a 45 N (10 lb) pull test on each of the wires in the DEF Repair: Repair the damaged wire or the damaged
pump connector and any connectors between the DEF pump and connector.
the ECM. Use the electronic service tool to clear all logged diag-
nostic codes. Verify that the repair eliminates the fault.
D. Check all the wiring associated with the DEF pump for abra-
sions and pinch points.

Note: Do not disconnect the ECM connector at this stage. The

ECM can only be disconnected and reconnected 10 times before
damage to the harness connector may occur.

2. Check that the DEF Pump is Grounded Correctly Less than 2 Result: The resistance is not within the expected range.
Ohms The fault is in the wiring between the DEF pump connec-
A. Turn the keyswitch to the OFF position. tor and battery (-).

B. Disconnect the harness connector from the DEF pump. Repair: Repair the faulty wiring or replace the faulty
wiring.
C. Measure the resistance between terminal 8 on the harness con-
nector for the DEF pump and a suitable ground. Result: The resistance is within the expected range.

Proceed to Test Step 3.

(continued)

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 M0095947-10 235
Circuit Tests

(Table 146, contd)

Troubleshooting Test Steps Values Results

3. Determine the Diagnostic Code Diagnostic Trou- Result: There is an active or logged 4374-4 or 4374-5
ble Codes diagnostic code.
A. Establish communication between the electronic service tool
and the engine Electronic Control Module (ECM). Refer to Trou- Proceed to Test Step 4.
bleshooting, “Electronic Service Tools”
There is an active or logged 4374-3 or 4374-6 diagnostic
B. Look for active or logged codes. code.

Proceed to Test Step 7.

4. Create a Short Circuit at the DEF Pump Harness Connector Short Circuit Result: A -5 diagnostic code was active before installing
the jumper. A -6 diagnostic code is active when the jump-
A. Turn the keyswitch to the OFF position. er is installed - There is a fault in the DEF pump.

B. Disconnect the DEF pump harness connector. Repair: Install a replacement DEF pump.

C. Fabricate a jumper wire that is 150 mm (6 inch) long. Result: A -3 diagnostic code was active before installing
the jumper. A -4 diagnostic code is active when the jump-
D. Install the wire between terminal 9 and terminal 10 on the DEF er is installed - There is a fault in the DEF pump.
pump connector to create a short circuit.
Repair: Install a replacement DEF pump.
E. Turn the keyswitch to the ON position. Use the electronic serv-
ice tool to start the “DEF Dosing System Verification Test” . This Use the electronic service tool to perform the “DEF Dos-
test will command the DEF pump on. ing System Verification Test” to check that the repair
eliminates the fault.
F. Check for active diagnostic codes.
Result: The original diagnostic code is still active with
G. Use the electronic service tool to stop the “DEF Dosing System the jumper installed.
Verification Test” . Remove the jumper wire from the DEF pump
connector. Remove the jumper. Reconnect all connectors. Proceed
to Test Step 5.

5. Check the Wiring Between the DEF Pump Connector and Less than 2 Result: The resistance is greater than 2 Ohms - There is
the Interface Connector (if equipped) for an Open Circuit Ohms a fault in the wiring between the DEF pump connector
and the interface connector.
Note: This step is only applicable if an interface connector is in-
stalled between the DEF pump and the ECM. Refer to the Electri- Repair: Repair the faulty wiring or replace the faulty
cal Schematic for the application for more information. Proceed to wiring.
Test Step 6 if no interface connector is installed.
Use the electronic service tool to perform the “DEF Dos-
A. Turn the keyswitch to the OFF position. ing System Verification Test” to check that the repair
eliminates the fault.
B. Disconnect the DEF Pump connector. Disconnect the interface
connector between the DEF pump and the ECM. Result: All measured resistances are less than 2 Ohms.

C. Use a suitable multimeter to measure the resistance between Reconnect all connectors. Proceed to Test Step 6.
terminal 10 on the DEF pump harness connector and the appropri-
ate pin/terminal on the interface connector.

D. Use a suitable multimeter to measure the resistance between

terminal 9 on the DEF pump harness connector and the appropri-
ate pin/terminal on the interface connector.

(continued)

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 236 M0095947-10
Circuit Tests

(Table 146, contd)

Troubleshooting Test Steps Values Results

6. Check the Wiring to the ECM for an Open Circuit Less than 2 Result: The resistance is greater than 2 Ohms. The fault
Ohms is in the wiring connected to the ECM connector.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty
B. Disconnect the P1 and P2 connectors. Disconnect the DEF wiring.
pump connector.
Result: The resistance is less than 2 Ohms.
C. Inspect the P1/J1 and P2/J2 connectors for damage or corro-
sion. Refer to Troubleshooting, Electrical Connectors - Inspect for Contact the Dealer Solutions Network (DSN).
more information.

D. Perform a 30 N (6.7 lb) pull test on P2:96 and P2:16.

E. Use a suitable multimeter to measure the resistance between

terminal 9 on the harness connector for the DEF pump and P2:96.

E. Use a suitable multimeter to measure the resistance between

terminal 10 on the harness connector for the DEF pump and
P1:16.

7. Create an Open Circuit at the DEF Pump connector Open circuit Result: A -6 diagnostic code was active before discon-
necting the DEF pump. A -5 diagnostic code is active
A. Turn the keyswitch to the OFF position. with the DEF pump disconnected. The fault is in the DEF
pump.
B. Disconnect the DEF pump connector.
Repair: Install a replacement DEF pump.
C. Turn the keyswitch to the ON position. Use the electronic serv- Use the electronic service tool to perform the “DEF Dos-
ice tool to start the “DEF Dosing System Verification Test” . This ing System Verification Test” to check that the repair
test will command the DEF pump on. eliminates the fault.

D. Check for active diagnostic codes. Result: A -4 diagnostic code was active before discon-
necting the DEF pump. A -3 diagnostic code is active
with the DEF pump disconnected. The fault is in the DEF
pump.

Repair: Install a replacement DEF pump.

Use the electronic service tool to perform the “DEF Dos-
ing System Verification Test” to check that the repair
eliminates the fault.

Result: The original diagnostic code is still active with

the DEF pump disconnected.

Proceed to Test Step 8.

(continued)

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 M0095947-10 237
Circuit Tests

(Table 146, contd)

Troubleshooting Test Steps Values Results

8. Check the Wiring Between the DEF Pump and the Interface Greater than 1 k Result: At least one of the resistance measurements is
Connector (if equipped) for a Short Circuit Ohm less than 1 k Ohm. There is a fault in the wiring between
the DEF pump connector and the interface connector.
Note: This step is only applicable if an interface connector is in-
stalled between the DEF pump and the ECM. Refer to the Electri- Repair: Repair the faulty wiring or replace the faulty
cal Schematic for the application for more information. Proceed to wiring.
Test Step 9 if no interface connector is installed.
Use the electronic service tool to perform the “DEF Dos-
A. Turn the keyswitch to the OFF position. ing System Verification Test” to check that the repair
eliminates the fault.
B. Disconnect the DEF pump connector. Disconnect the interface
connector between the DEF pump and the ECM. Result: All measured resistances are greater than 1 k
Ohm.
C. Use a suitable multimeter to measure the resistance between
the DEF pump signal terminal on the interface connector and all Reconnect all connectors. Proceed to Test Step 9.
other terminals on the interface connector.

9. Check the Wiring to the ECM for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is
Ohm less than 1 k Ohm. The fault is in the wiring connected to
A. Turn the keyswitch to the OFF position. the ECM connector.

B. Disconnect the P1 connector. Disconnect the DEF pump Repair: Repair the faulty wiring or replace the faulty
connector. wiring.

C. Inspect the P1/J1 connectors for damage or corrosion. Refer to Result: All resistance measurements are greater than 1
Troubleshooting, Electrical Connectors - Inspect for more k Ohm.
information.
Contact the Dealer Solutions Network (DSN).
D. Perform a 30 N (6.7 lb) pull test on P1:16.

E. Use a suitable multimeter to measure the resistance between

P1:16 and all other terminals on the P1 connector.

i07483441

DEF Pump Pressure Sensor -

Test

Table 147 lists the diagnostic codes for the Diesel

Exhaust Fluid (DEF) pump pressure sensor circuit.
Table 147
Diagnostic Trouble Codes for the DEF Pump Pressure Sensor

J1939 Code Code Description Comments

Aftertreatment 1 Diesel Exhaust There is excessive voltage on the signal wire between the Electronic Control Module
Fluid Doser 1 Absolute Pressure : (ECM) and the DEF pump.
4334-3 Voltage Above Normal or
There is an open circuit on the supply, signal, or return wire.
The code is logged.

Aftertreatment 1 Diesel Exhaust There is low voltage on the signal wire between the DCU and the DEF pump pressure
4334-4 Fluid Doser 1 Absolute Pressure : sensor.
Voltage Below Normal The code is logged.

Follow the troubleshooting procedure to identify the root cause of the problem.

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 238 M0095947-10
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Table 148
Required Tools

Tool Part Number Part Description Qty

A T4000242 Break-out Connector 1

Illustration 32 g06334650

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the DEF pump connector
and the ECM connectors.

Illustration 33 g03811015
Pin location on the DEF pump connector
(8) Return
(9) 12V supply
(10) PWM signal

Complete the procedure in the order in which the

steps are listed.

This document has been printed from SPI2. NOT FOR RESALE
 M0095947-10 239
Circuit Tests

Table 149
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Damaged wire or Result: A damaged wire or damaged connector
connector was not found.
A. Inspect the connector for the DEF pump.
Proceed to Test Step 2.
B. Thoroughly inspect any connectors between the DEF pump
and the ECM. Refer to Troubleshooting, “Electrical Connectors - Result: A damaged wire or damaged connector
Inspect” for details. was found.

C. Perform a 30 N (6.7 lb) pull test on each of the wires in the Repair: Repair the damaged wire or the dam-
DEF pump connector and any connectors between the DEF aged connector.
pump and the ECM.
Use the electronic service tool to clear all logged
D. Check all the wiring associated with the DEF pump for abra- diagnostic codes. Verify that the repair eliminates
sions and pinch points. the fault.

Note: Do not disconnect the ECM connector at this stage. The

ECM can only be disconnected and reconnected 10 times before
damage to the harness connector may occur.

2. Check the 5V Supply to the DEF Pump Pressure Sensor Between 4.84V and Result: The voltage measurement is not within
5.16V the expected range.
A. Turn the keyswitch to the OFF position.
If an interface connector is installed between the
B. Disconnect the connector for the DEF pump. DEF pump and the ECM, proceed to Test Step 3.
If no interface connector is installed between the
C. Turn the keyswitch to the ON position. DEF pump and the ECM, the fault is in the
ground or 5V supply wiring to the DEF pump.
D. Use a suitable multimeter to measure the voltage between ter- Repair the faulty wiring or replace the faulty wir-
minal 2 and terminal 4 on the harness connector for the DEF ing. Use the electronic service tool to perform the
pump. “DEF Dosing System Verification Test” to check
that the repair eliminates the fault.

Result: The voltage measurement is within the

expected range.

Proceed to Test Step 4.

3. Check the 5V Supply to the Interface Connector Between 4.84V and Result: The voltage measurement is not within
5.16V the expected range.
Note: This step is only applicable if an interface connector is in-
stalled between the DEF pump and the ECM. Refer to the Electri- Repair: The fault is in the 5V supply wiring or the
cal Schematic for the application for more information. Proceed to ground wiring between the interface connector
Test Step 6 if no interface connector is installed. and the ECM.
Repair the faulty wiring or replace the faulty wir-
A. Turn the keyswitch to the OFF position. ing. Use the electronic service tool to perform the
“DEF Dosing System Verification Test” to check
B. Disconnect the interface connector. that the repair eliminates the fault.

C. Use a suitable multimeter to measure the voltage between the Result: The voltage measurement is within the
sensor supply terminal and the sensor ground terminal on the in- expected range.
terface connector.
Proceed to Test Step 4.

(continued)

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 240 M0095947-10
Circuit Tests

(Table 149, contd)

Troubleshooting Test Steps Values Results

4. Determine the Diagnostic Code Diagnostic trouble codes Result: There is an active logged 4334-4 diag-
nostic code.
A. Establish communication between the electronic service tool
and the engine Electronic Control Module (ECM). Refer to Trou- Proceed to Test Step 5.
bleshooting, “Electronic Service Tools”
Result: There is an active 4334-3 diagnostic
B. Check for active or logged codes. code.

Proceed to Test Step 8.

5. Create an Open Circuit at the DEF Pump Connector Diagnostic codes Result: A 4334-4 diagnostic code was active be-
fore disconnecting the DEF pump. A 4334-3 diag-
A. Turn the keyswitch to the OFF position. nostic code became active after disconnecting
the DEF pump.
B. Disconnect the DEF pump harness connector.
Repair: The fault is in the DEF pump pressure
C. Turn the keyswitch to the ON position. Wait at least 30 seconds sensor.
for activation of the diagnostic codes. Install a replacement DEF pump. Use the elec-
tronic service tool to perform the “DEF Dosing
D. Use the electronic service tool to check for an active 4334-3 di- System Verification Test” to check that the repair
agnostic code. eliminates the fault.

Result: The 4334–4 diagnostic code is still

active.

Proceed to Test Step 6.

6. Create an Open Circuit at the Interface Connector (if Greater than 1k Ohm Result: A 4334-4 diagnostic code was active be-
equipped fore disconnecting the interface connector. A
4334-3 diagnostic code became active after dis-
Note: This step is only applicable if an interface connector is in- connecting the interface connector.
stalled between the DEF pump and the ECM. Refer to the Electri-
cal Schematic for the application for more information. Proceed to Repair: The fault is in the wiring between the in-
Test Step 7 if no interface connector is installed. terface connector and the DEF pump connector.
Repair the faulty wiring or replace the faulty wir-
A. Turn the keyswitch to the OFF position. ing. Use the electronic service tool to perform the
“DEF Dosing System Verification Test” to check
B. Disconnect the interface connector between the DEF pump that the repair eliminates the fault.
and the ECM.
Result: The 4334–4 diagnostic code is still
C. Turn the keyswitch to the ON position. Use the electronic serv- active.
ice tool to start the “DEF Dosing System Verification Test” . This
test will command the DEF pump on. Proceed to Test Step 7.

D. Check for active diagnostic codes.

(continued)

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 M0095947-10 241
Circuit Tests

(Table 149, contd)

Troubleshooting Test Steps Values Results

7. Check the Wiring to the ECM for a Short Circuit Diagnostic codes Result: At least one of the resistance measure-
ments is less than 1 k Ohm. The fault is in the wir-
A. Turn the keyswitch to the OFF position. ing connected to the ECM connector.

B. Disconnect the P1 connector. Disconnect the DEF pump Repair: Repair the faulty wiring or replace the
connector. faulty wiring.
Use the electronic service tool to perform the
C. Inspect the P1/J1 connectors for damage or corrosion. Refer “DEF Dosing System Verification Test” to check
to Troubleshooting, Electrical Connectors - Inspect for more that the repair eliminates the fault.
information.
Result: All resistance measurements are greater
D. Perform a 30 N (6.7 lb) pull test on P1:23. than 1 k Ohm.

E. Use a suitable multimeter to measure the resistance between Contact the Dealer Solutions Network (DSN).
P1:23 and all other terminals on the P1 connector.

8. Create a Short Circuit at the DEF Pump Harness Connector Diagnostic codes Result: A 4334–3 diagnostic code was active be-
fore installing the jumper. A 4334–4 diagnostic
A. Turn the keyswitch to the OFF position. code is active when the jumper is installed -
There is a fault in the DEF pump pressure
B. Disconnect the DEF pump harness connector. sensor.

C. Fabricate a jumper wire that is 150 mm (6 inch) long. Repair: Install a replacement DEF pump.

D. Install the wire between terminal 3 and terminal 4 on the DEF Use the electronic service tool to perform the
pump connector to create a short circuit. “DEF Dosing System Verification Test” to check
that the repair eliminates the fault.
E. Turn the keyswitch to the ON position. Use the electronic serv-
ice tool to start the “DEF Dosing System Verification Test” . This Result: A 4334–3 diagnostic code is still active
test will command the DEF pump on. with the jumper installed.

F. Check for active diagnostic codes. Remove the jumper. Reconnect all connectors.
Proceed to Test Step 9.
G. Use the electronic service tool to stop the “DEF Dosing System
Verification Test” . Remove the jumper wire from the DEF pump
connector.

(continued)

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 242 M0095947-10
Circuit Tests

(Table 149, contd)

Troubleshooting Test Steps Values Results

9. Create a Short Circuit at the Interface Connector (if Diagnostic codes Result: A 4334–3 diagnostic code was active be-
equipped) fore installing the jumper. A 4334–4 diagnostic
code is active when the jumper is installed -
Note: This step is only applicable if an interface connector is in- There is a fault in the wiring between the interface
stalled between the DEF pump and the ECM. Refer to the Electri- connector and the DEF pump connector.
cal Schematic for the application for more information. Proceed to
Test Step 10 if no interface connector is installed. Repair: Repair the faulty wiring or replace the
faulty wiring.
A. Turn the keyswitch to the OFF position.
Use the electronic service tool to perform the
B. Disconnect the interface connector between the DEF pump “DEF Dosing System Verification Test” to check
and the ECM. that the repair eliminates the fault.

C. Fabricate a jumper wire that is 150 mm (6 inch) long. Result: A 4334–3 diagnostic code is still active
with the jumper installed.
D. Install the wire between the sensor signal terminal and the sen-
sor ground terminal to create a short circuit. Remove the jumper. Reconnect all connectors.
Proceed to Test Step 10.
E. Turn the keyswitch to the ON position. Use the electronic serv-
ice tool to start the “DEF Dosing System Verification Test” . This
test will command the DEF pump on.

F. Check for active diagnostic codes.

G. Use the electronic service tool to stop the “DEF Dosing System
Verification Test” . Remove the jumper wire from the interface
connector.

10. Check the Wiring to the ECM for an Open Circuit Less than 2 Ohms Result: The resistance is greater than 2 Ohms.
The fault is in the wiring connected to the ECM
A. Turn the keyswitch to the OFF position. connector.

B. Disconnect the P1 connector. Disconnect the DEF pump Repair: Repair the faulty wiring or replace the
connector. faulty wiring.
Use the electronic service tool to perform the
C. Inspect the P1/J1 connectors for damage or corrosion. Refer “DEF Dosing System Verification Test” to check
to Troubleshooting, Electrical Connectors - Inspect for more that the repair eliminates the fault.
information.
Result: The resistance is less than 2 Ohms.
D. Perform a 30 N (6.7 lb) pull test on P1:23.
Contact the Dealer Solutions Network (DSN).
E. Use a suitable multimeter to measure the resistance between
terminal 3 on the harness connector for the DEF pump and
P1:23.

i07488417

DEF Return Valve - Test

Table 150 lists the diagnostic codes for the Diesel

Exhaust Fluid (DEF) pump return valve circuit.

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 M0095947-10 243
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Table 150
Diagnostic Trouble Codes for the DEF Return Valve

J1939 Code Code Description Comments

Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit This code indicates that there is problem with the DEF pump reversing
4376-5
1 Diverter Valve : Current Below Normal valve or the Pump Electronic Tank Unit (PETU) wiring harness.

Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit This code indicates that there is problem with the DEF pump reverting
4376-6
1 Diverter Valve : Current Above Normal valve or the PETU wiring harness.

Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit The ECM detects that the return valve is not responding properly.
4376–7
1 Diverter Valve : Not Responding Properly The code is logged.

Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit A loss of power to the DEF pump reversing valve was detected before the
4376–14
1 Diverter Valve : Special Instruction DEF purge cycle was completed.

Follow the troubleshooting procedure to identify the root cause of the problem.

Illustration 34 g06335831
Schematic diagram for the DEF reversing valve circuit

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the DEF reversing valve
relay connector and the ECM connector.

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 244 M0095947-10
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Illustration 35 g03417188
Pin locations for the DEF return valve on the DEF
pump connector
(11) Reversing valve return
(12) Reversing valve supply

Table 151
Required Tools

Tool Part Number Part Description Qty

A T4000242 Break-out Connector 1

Complete the procedure in the order in which the

steps are listed.

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 M0095947-10 245
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Table 152
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was not
or connector found.
A.Thoroughly inspect the connector for the DEF pump. Refer to
Troubleshooting, “Electrical Connectors - Inspect” for details. Proceed to Test Step 2.

B. Thoroughly inspect the connector for the DEF reversing valve Result: A damaged wire or damaged connector was
relay. Refer to Troubleshooting, “Electrical Connectors - Inspect” found.
for details.
Repair: Repair the damaged wire or the damaged
C. Thoroughly inspect any connectors between the DEF reversing connector.
valve relay and the ECM. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details. Use the electronic service tool to clear all logged diag-
nostic codes. Verify that the repair eliminates the fault.
D. Perform a 30 N (10 lb) pull test on each of the wires in the con-
nector for the DEF pump and the DEF reversing valve relay.

E. Check all the wiring associated with the DEF reversing valve for
abrasions and pinch points.

Note: Do not disconnect the ECM connector at this stage. The

ECM can only be disconnected and reconnected 10 times before
damage to the harness connector may occur.

2. Determine the Diagnostic Code Diagnostic trou- Result: There is an active or logged 4376-5 diagnostic
ble codes code.
A. Establish communication between the electronic service tool
and the engine Electronic Control Module (ECM). Refer to Trou- Proceed to Test Step 3.
bleshooting, “Electronic Service Tools”.
Result: There is an active 4376–6 diagnostic code.
B. Check for active or logged codes.
Proceed to Test Step 6.

Result: There is an active or logged 4376–7 or 4376–14

diagnostic code.

Proceed to Test Step 9.

(continued)

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(Table 152, contd)

Troubleshooting Test Steps Values Results

3. Create a Short Circuit at the DEF Reversing Valve Relay Diagnostic Result: A 4376–5 diagnostic code was active before in-
codes stalling the jumper. A 4376–6 diagnostic code is active
A. Turn the keyswitch to the OFF position for 2 minutes. The key- with the jumper installed.
switch must be OFF for 2 minutes to allow the DEF pump to purge,
reset the code, and reset the Diesel Exhaust Fluid Controller Repair: The fault is in the DEF reversing valve relay.
(DCU). Install a replacement relay. Use the electronic service
tool to enable the “DEF Return Valve #1 Override” to veri-
B. Disconnect the harness connector from the DEF reversing fy that the repair eliminates the fault.
valve relay.
Result: The 4376–5 diagnostic code is still active with
C. Fabricate a jumper wire that is 150 mm (6 inch) long. the jumper installed.

D. Install the wire between Test Point 1 and Test Point 2 on the Proceed to Test Step 4.
harness connector for the DEF reversing valve relay.

E. Turn the keyswitch to the ON position.

F. Use the electronic service tool to enable the “DEF Return Valve
#1 Override” . Check for active diagnostic codes.

G. Use the electronic service tool to disable the “DEF Return Valve
#1 Override” .

4. Check the Wiring Between the DEF Reversing Valve Relay Less than 2 Result: The resistance is greater than 2 Ohms - There is
and the Interface Connector (if equipped) for an Open Circuit Ohms a fault in the wiring between the DEF reversing valve re-
lay connector and the interface connector.
Note: This step is only applicable if an interface connector is in-
stalled between the DEF reversing valve relay and the ECM. Refer Repair: Repair the faulty wiring or replace the faulty wir-
to the Electrical Schematic for the application for more information. ing. Use the electronic service tool to enable the “DEF
Proceed to Test Step 5 if no interface connector is installed. Return Valve #1 Override” to verify that the repair elimi-
nates the fault.
A. Turn the keyswitch to the OFF position.
Result: All measured resistances are less than 2 Ohms.
B. Disconnect the connector for DEF reversing valve relay. Dis-
connect the interface connector between the relay and the ECM. Reconnect all connectors. Proceed to Test Step 5.

C. Use a suitable multimeter to measure the resistance between

Test Point 2 on the harness connector for the relay and the appro-
priate pin/terminal on the interface connector.

(continued)

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 M0095947-10 247
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(Table 152, contd)

Troubleshooting Test Steps Values Results

5. Check the Wiring to the ECM for an Open Circuit Less than 2 Result: The resistance is greater than 2 Ohms. The fault
Ohms is in the wiring connected to the ECM connector.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty
B. Disconnect the P1 connector. Disconnect the DEF reversing wiring.
valve relay connector.
Result: The resistance is less than 2 Ohms.
C. Inspect the P1/J1 connectors for damage or corrosion. Refer to
Troubleshooting, Electrical Connectors - Inspect for more Contact the Dealer Solutions Network (DSN).
information.

D. Perform a 30 N (6.7 lb) pull test on P1:40 and P1:41.

E. Use a suitable multimeter to measure the resistance between

Test Point 2 on the harness connector for the relay and P1:40.
Use a suitable multimeter to measure the resistance between Test
Point 2 on the harness connector for the relay and P1:41.

6. Create an Open Circuit at the DEF Reversing Valve Relay Diagnostic Result: A 4376-6 diagnostic code was active before dis-
codes connecting the DEF reversing valve relay. A 4376–5 di-
A. Turn the keyswitch to the OFF position. agnostic code is active with the DEF reversing valve
relay disconnected. The fault is in the relay.
B. Disconnect the connector for the DEF reversing valve relay.
Repair: Install a replacement DEF reversing valve relay.
C. Turn the keyswitch to the ON position. Use the electronic serv- Use the electronic service tool to enable the “DEF Return
ice tool to enable the “DEF Return Valve #1 Override” . Valve #1 Override” to verify that the repair eliminates the
fault.
D. Check for active diagnostic codes.
Result: The 4376–6 diagnostic code is still active with
E. Use the electronic service tool to disable the “DEF Return Valve the relay disconnected.
#1 Override” .
Proceed to Test Step 7.

7. Check the Wiring Between the DEF Reversing Valve Relay Greater than 1 k Result: At least one of the resistance measurements is
and the Interface Connector (if equipped) for a Short Circuit Ohm less than 1 k Ohm. There is a fault in the wiring between
the DEF reversing valve relay connector and the inter-
Note: This step is only applicable if an interface connector is in- face connector.
stalled between the DEF reversing valve relay and the ECM. Refer
to the Electrical Schematic for the application for more information. Repair: Repair the faulty wiring or replace the faulty
Proceed to Test Step 8 if no interface connector is installed. wiring.

A. Turn the keyswitch to the OFF position. Use the electronic service tool to enable the “DEF Return
Valve #1 Override” to verify that the repair eliminates the
B. Disconnect the DEF reversing valve relay connector. Discon- fault.
nect the interface connector between the relay and the ECM.
Result: All measured resistances are greater than 1 k
C. Use a suitable multimeter to measure the resistance between Ohm.
the DEF reversing valve return terminal on the interface connector
and all other terminals on the interface connector. Reconnect all connectors. Proceed to Test Step 8.

(continued)

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(Table 152, contd)

Troubleshooting Test Steps Values Results

8. Check the Wiring to the ECM for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is
Ohm less than 1 k Ohm. The fault is in the wiring connected to
A. Turn the keyswitch to the OFF position. the ECM connector.

B. Disconnect the P1 connector. Disconnect the connector for the Repair: Repair the faulty wiring or replace the faulty
DEF reversing valve relay. wiring.
Use the electronic service tool to enable the “DEF Return
C. Inspect the P1/J1 connectors for damage or corrosion. Refer to Valve #1 Override” to verify that the repair eliminates the
Troubleshooting, Electrical Connectors - Inspect for more fault.
information.
Result: All resistance measurements are greater than 1
D. Perform a 30 N (6.7 lb) pull test on P1:40 and P1:41. k Ohm.

E. Use a suitable multimeter to measure the resistance between Contact the Dealer Solutions Network (DSN).
P1:40 and all other terminals on the P1 connector.
Use a suitable multimeter to measure the resistance between
P1:41 and all other terminals on the P1 connector.

9. Ensure That the Correct Engine Shutdown Procedure is Shutdown Result: The correct procedure to shut down the engine
Followed procedure was not used.

A. Ensure that the correct procedure is being used to shut down Repair: Use the correct procedure to shut down the en-
the engine. Refer to Operation and Maintenance Manual, Stop- gine. Refer to Operation and Maintenance Manual, Stop-
ping the Engine for the correct procedure. ping the Engine for the correct procedure.

The ECM requires that electrical power remains on to

complete the DEF purge cycle.

Result:The correct procedure to shut down the engine is

being used.

Proceed to Test Step 10.

At least 12.5 V
10. Check the Voltage to the DEF Reversing Valve Relay for a 12 V Result: The measured voltage is not within the expected
system range. The fault is in the wiring between the DEF revers-
A. Turn the keyswitch to the OFF position. At least 25V for ing valve relay and the SCR relay.
a 24V system
B. Disconnect the DEF reversing valve relay. Repair: Repair the faulty wiring or replace the faulty
wiring.
C. Turn the keyswitch to the ON position. Use the electronic service tool to enable the “DEF Return
Valve #1 Override” to verify that the repair eliminates the
D. Use a suitable multimeter to measure the voltage between Test fault.
Point 1 on the harness connector for the relay and a suitable
ground. Refer to illustration 34 . Result: The voltage measurements are within the ex-
Use a suitable multimeter to measure the voltage between Test pected range.
Point A on the harness connector for the relay and a suitable
ground. Refer to illustration 34 . Proceed to Test Step 11.

(continued)

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(Table 152, contd)

Troubleshooting Test Steps Values Results
At least 12.5 V
11. Check the Voltage for the DEF Reversing Valve at the DEF for a 12 V Result: The measured voltage is within the expected
Pump system range. The DEF reversing valve relay and the wiring to
At least 25V for the DEF pump are OK.
A. Turn the keyswitch to the OFF position. a 24V system
Repair: Install a replacement DEF pump.
B. Disconnect the connector for the DEF pump. Use the electronic service tool to enable the “DEF Return
Valve #1 Override” to verify that the repair eliminates the
C. Turn the keyswitch to the ON position. fault.

D. Use the electronic service tool to enable the “DEF Return Valve Result: The measured voltage is not within the expected
#1 Override” . range.

E. Use a suitable multimeter to measure the voltage between ter- Proceed to Test Step 12.
minal 11 and terminal 12 on the harness connector for the DEF
pump.

F. Use the electronic service tool to disable the “DEF Return Valve
#1 Override” .

At least 12.5 V
12. Bypass the DEF Reversing Valve Relay and Check the for a 12 V Result: The voltage is within the expected range. The
Voltage at the DEF Pump system fault is in the DEF reversing valve relay.
At least 25V for
A. Turn the keyswitch to the OFF position. a 24V system Repair: Install a replacement relay.
Use the electronic service tool to enable the “DEF Return
B. Disconnect the connector for the DEF pump. Disconnect the Valve #1 Override” to verify that the repair eliminates the
connector for the DEF reversing valve relay. fault.

C. Fabricate a jumper wire that is 150 mm (6 inch) long. Result: The voltage is not within the expected range.
The fault is in the ground wiring or the supply wiring to
D. Install the jumper wire between Test Point A and Test Point B the DEF pump reversing valve.
on the harness connector for the relay. Refer to Illustration 34 .
Repair: Repair the faulty wiring or replace the fault wiring
E. Turn the keyswitch to the ON position. Use the electronic service tool to enable the “DEF Return
Valve #1 Override” to verify that the repair eliminates the
F. Use a suitable multimeter to measure the voltage between ter- fault.
minal 11 and terminal 12 on the harness connector for the DEF
pump.

i07496819

DEF Tank Sensor - Test

Use this procedure to troubleshoot the electrical

system if a fault is suspected with the sensors. Use
this procedure if any of the diagnostic codes in Table
153 are active or easily repeated.

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Table 153
Diagnostic Codes Table

J1939 Code Code Description Comments

The ECM detects that the DEF Level measurement re-
ceived from the DEF Tank Sensor is not within the ac-
ceptable range.
or
Aftertreatment #1 Diesel Exhaust Fluid Tank Level: Erratic The DEF Level measurement received from the DEF
1761-2
Intermittent or Incorrect Tank Sensor has shown an invalid drop in level meas-
urement within a monitoring window.
The code is logged if the DEF level measurement does
not resolve into acceptable measurement range after a
time delay.

The ECM detects a failure of the level sensor.

1761-12 Aftertreatment 1 Diesel Exhaust Fluid Tank Level : Failure
The code is logged.

Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature : The ECM detects a failure of the temperature sensor.
3031-12
Failure The code is logged.

The ECM detects that the DEF Quality measurement

received from the DEF Tank Sensor over the datalink is
not within the acceptable range.
or
Aftertreatment #1 DEF Concentration : Erratic, Intermittent, The DEF Quality measurement received from the DEF
3516-2
or Incorrect Tank Sensor has shown an invalid quality measure-
ment within a monitoring window.
The code is logged if the DEF quality measurement
does not resolve into acceptable measurement range
after a time delay.

The ECM detects a failure of the quality sensor.

3516-12 Aftertreatment #1 DEF Concentration : Failure
The code is logged.

Battery voltage is routed to terminal 4 of the tank

header unit. The return is routed to terminal 3 of the
tank header unit. The temperature, level, and quality
signals are routed through the CAN C data link on
terminal 2 (CAN C+) and terminal 1 (CAN C-). The
ECM provides short circuit protection for the internal
power supply. A short circuit to the battery will not
damage the internal power supply.

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Illustration 36 g06409969
Schematic for the DEF tank header unit

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the DEF reversing valve
relay connector and the ECM connector.

Illustration 37 g03700612
(1) DEF tank header electrical connector
(2) DEF tank header

If possible, the machine should be on a level

surface before the following procedure is
performed.
The tank header unit houses the DEF tank
temperature, the DEF tank level, and the DEF
quality sensors. The sensors are not serviceable
individually.
Complete the procedure in the order in which the
steps are listed.

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Table 154
Troubleshooting Test Steps Values Results

1. Check for Diagnostic Codes Diagnostic Result: A -12 diagnostic code is active.
code
A. Establish communication between the electronic service tool and Proceed to Test Step 2.
the ECM . Refer to Troubleshooting, “Electronic Service Tools”, if
necessary. Result: A 1761-2 code is active.

B. Turn the keyswitch to the ON position. Proceed to Test Step 4.

C. Look for active or logged codes. Result: A 3516-2 code is active.

Proceed to Test Step 5.

2. Check for Battery Voltage at the DEF Tank Header Battery voltage Result: The measured voltage is not equal to battery
voltage. The fault is in the power supply wiring to the
A. Disconnect the harness at the DEF tank header. DEF tank header.

B. Turn the keyswitch to the ON position. Repair: Repair the faulty wiring or replace the faulty
wiring.
C. Measure the voltage between terminals 3 and 4 on the harness
connector for the DEF tank header. Result: The measured voltage is equal to battery
voltage.
D. Turn the keyswitch to the OFF position.
Proceed to Test Step 3.

3. Connect a Replacement DEF Tank Header Unit DEF tank head- Result: No -12 diagnostic codes are active.
er replacement
A. Disconnect the connector from the DEF tank header unit. Repair: Install the replacement DEF tank header unit.
Confirm that the fault has been eliminated.
B. Connect a replacement DEF tank header unit to the harness. Do
not install the unit. Result: A -12 diagnostic code is active.

C. Connect the electronic service tool. Reconnect the harness connector to the original DEF
tank header unit.
D. Turn the keyswitch to the ON position. Wait for at least 2 minutes. Contact the Dealer Solutions Network (DSN).

E. Check for -12 codes.

4. Ensure that the Application is on a Level Gradient DEF Level Result: The DEF level indicates a value between 0 per-
cent and 100 percent.
A. If necessary, move the application to a level gradient.
Return the engine to service.
B. Wait at least 2 minutes. Turn the keyswitch to the ON position.
Result: The DEF level indicates “Conditions Not Met” 2
C. Connect to the electronic service tool. minutes after the application has been moved to a level
gradient.
D. Use the electronic service tool to check the DEF level
measurement. Proceed to Test Step 5.
Note: Use the electronic service tool for this step and not a gauge
on the application.

(continued)

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 M0095947-10 253
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(Table 154, contd)

Troubleshooting Test Steps Values Results
DEF Level
5. Flush the DEF Tank and Refill the DEF Tank Result: The DEF level indicates a value between 0 per-
cent and 100 percent 2 minutes after the DEF tank has
A. Turn the keyswitch to the OFF and ensure that the “Wait to Dis- been filled.
connect” lamp has switched off.
Return the engine to service.
B. Flush the DEF tank and refill the DEF tank. Refer to Operation
and Maintenance Manual, “Diesel Exhaust Fluid Tank - Flush” for Result: The DEF level indicates “Conditions Not Met” 2
the correct procedure. minutes after the DEF tank has been filled.
Note: Only use DEF that meets ISO 22241 standards.
Proceed to Test Step 6.
C. Turn the keyswitch to the ON position.

D. Use the electronic service tool to check the DEF level

measurement.
Note: Use the electronic service tool for this step and not a gauge
on the application.

6. Inspect the DEF Tank Header Correct opera- Result: The level sensor is damaged or debris is
tion of level and present.
A. Turn the keyswitch to the OFF position. quality sensors
Repair: Turn the keyswitch to the ON position. Wait for
B. Remove tank header (2) from the DEF tank. Refer to Disassembly 2 minutes. If the DEF level in the electronic service tool
and Assembly, “Manifold (DEF Heater) - Remove and Install”. indicates “Conditions Not Met” , replace the DEF tank
header.
C. Inspect the DEF tank header for damage or debris to the sensor
pick-up tube. Result: The DEF temperature is greater than 0° C
(32° F) and the 3516-2 code is still active.

Repair: Replace the DEF tank header.

If the fault is still present, contact the Dealer Solutions

Network (DSN).

i07523464

Electrical Power Supply - Test

Use this procedure to troubleshoot the electrical

system if a problem is suspected with the power to
the engines Electronic Control Module (ECM). Use
this procedure if any of the diagnostic codes in Table
155 are active or easily repeated.
Table 155
Diagnostic Trouble Codes for the Electrical Power Supply

J1939 Code Code Description Comments

168-15 Battery Potential / Power Input #1 : High - least severe The ECM detects voltage that is above the acceptable
(1) value.

168-17 Battery Potential / Power Input #1 : Low - least severe The ECM detects voltage that is below the acceptable
(1) value.

The engine ECM requires the keyswitch to be in the

ON position to maintain communications with the
electronic service tool.

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Illustration 38 g06348960
Schematic diagram for the engine electrical power supply circuit
Not all connectors are shown. Refer to the appropriate electrical schematic

Complete the procedure in the order in which the

steps are listed.
Table 156
Troubleshooting Test Steps Value Results

1. Determine the Diagnostic Code Diagnostic code Result: One of the diagnostic codes listed in Table 155 is
active.
A. Establish communication between the electronic service
tool and the ECM . Refer to Troubleshooting, “Electronic Proceed to Test Step 2.
Service Tools”, if necessary.
Result: The electronic service tool will not communicate with
B. Start the engine. Run the engine until the engine is at nor- the ECM.
mal operating temperature.
Repair: Refer to Troubleshooting, “Electronic Service Tool
C. Observe the “Active Diagnostic” screen on the electronic Does Not Communicate”.
service tool. Wait at least 30 seconds so that any codes may
become active.

(continued)

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 M0095947-10 255
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(Table 156, contd)

2. Inspect Electrical Connectors and Wiring Damaged wire or Result: A damaged wire or damaged connector was found. A
connector. Blown blown fuse was found.
A. Ensure that the battery disconnect switch is in the fuse.
CLOSED position. Repair: Repair the damaged wire or the damaged connector.
Replace all blown fuses.
B. Thoroughly inspect all connectors associated with the Use the electronic service tool to clear all logged diagnostic
electrical power supplies. codes. Verify that the repair eliminates the fault.

C. Check all fuses. Result: The “System Operating Voltage Configuration” is

configured incorrectly.
D. Perform a 30 N (6.7 lb) pull test on each of the wires in
the connectors associated with the electrical power supplies. Repair: Program the parameter with the correct system
voltage.
E. Check all the wiring associated with the electrical power
supplies for abrasions and pinch points. Result: A damaged wire or damaged connector was not
found. The fuses are OK.
F. Verify that the “System Operating Voltage Configuration” is
correctly configured in the Engine ECM configuration Proceed to Test Step 3.
parameters.

3. Load Test the Batteries Load test Result: The batteries pass the load test.

A. Use a suitable battery load tester to test the batteries. Re- Proceed to Test Step 4.
fer to Systems Operation, Testing and Adjusting, “Battery -
Test” for the correct procedure.
Result: The batteries do not pass the load test.

Repair: Recharge or replace the faulty batteries.

Use the electronic service tool to clear all logged diagnostic

codes and verify that the repair eliminates the fault.

4. Check the Charging Circuit Charging circuit Result: The charging system is OK.

A. Check the charging circuit. Refer to Systems Operation, Contact the Dealer Solutions Network (DSN).
Testing and Adjusting, “Charging System - Test”.
Result: The charging system is not OK.

Repair: There is a fault in the charging system. Make the

necessary repairs.
Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.

i07816297

Engine Speed - Test

This procedure covers the following diagnostic

trouble code:

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Table 157
Diagnostic Trouble Codes for Engine Speed

J1939 Code Code Description Comments

The ECM has detected an unintended injector current command causing engine speed to
exceed a threshold above desired engine speed for a longer than allowable time.
Engine Speed : Abnormal Rate of
190-10
Change The engine will usually shut down.

Factory passwords are required to clear a 190–10 diagnostic code.

Probable Causes
• Wiring to the electronic unit injectors

• Electronic unit injectors

• Engine software and ECM

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

Electrical Shock Hazard. The electronic unit injec-

tors use DC voltage. The ECM sends this voltage
to the electronic unit injectors. Do not come in
contact with the harness connector for the elec-
tronic unit injectors while the engine is operating.
Failure to follow this instruction could result in
personal injury or death.

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 M0095947-10 257
Circuit Tests

Table 158
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Diagnostic codes Result: A diagnostic code is not active or logged.

A. Download the Product Status Report (PSR) with Histo- Return the unit to service.
grams before performing any troubleshooting or clearing any
diagnostic codes. Result: A 190–10 diagnostic code is active or logged.

Note: The downloaded information will be required by the Proceed to Test Step 2.
Dealer Solutions Network (DSN) if troubleshooting assis-
tance is needed.

B. Use the electronic service tool to check for active or

logged diagnostic codes.

2. Inspect Electrical Connectors and Wiring Loose connection Result: There is a fault in the connector or the wiring.
or damaged wire
A. Turn the keyswitch to the OFF position. A strong electrical Repair: Repair any faulty connectors or replace the wiring
shock hazard is present if the keyswitch is not turned OFF. harness. Ensure that all the seals are properly in place and
ensure that the connectors are correctly coupled.
B: Thoroughly inspect the connectors at the cylinder head. Use the electronic service tool to clear all logged diagnostic
Refer to Troubleshooting, Electrical Connectors - Inspect for codes and verify that the repair eliminates the fault.
details.
Result: All connectors, pins, and sockets are correctly
C. Perform a 30 N (6.7 lb) pull test on each of the wires in the coupled and/or inserted. The harness is free of corrosion,
ECM connector that are associated with the injector abrasion, and pinch points.
solenoids.
Proceed to Test Step 3.
D. Check the harness and wiring for abrasions and for pinch
points from the injectors to the ECM.

3. Use the “ Injector Solenoid Test”” “OK” , “OPEN” , Result: All cylinders indicate “OK” .
or “SHORT” There is not an electrical fault with the injectors.
A. Start the engine.

B. Allow the engine to warm up to the normal operating Proceed to Test Step 4.
temperature.
Result: “OPEN” or “SHORT” is indicated on any injector.
C. Stop the engine. Note the cylinders that indicate “OPEN” or “SHORT” .
Refer to Troubleshooting, Injector Solenoid - Test to diag-
D. Turn the keyswitch to the ON position. nose the cause of the injector circuit fault.

E. Access the “Injector Solenoid Test” in the electronic serv-

ice tool by accessing the following screens:

• Diagnostics
• Diagnostic Tests
• Injector Solenoid Test

F. Activate the test.

Note: Do not confuse the “Injector Solenoid Test” with the

“Cylinder Cutout Test” . The “Cylinder Cutout Test” is used to
shut off fuel to a specific cylinder while the engine is running.
The “Injector Solenoid Test” is used to actuate the injector
solenoids while the engine is not running.

(continued)

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(Table 158, contd)

Troubleshooting Test Steps Values Results

4. Electronic Unit Injectors Electronic unit Result: A faulty cylinder is indicated.

injectors
A. Use the electronic service tool to perform the automatic Repair: Remove any faulty electronic unit injectors. Refer to
“Cylinder Cutout Test” . Refer to Troubleshooting, Service Disassembly and Assembly, Electronic Unit Injector -
Tool Features for more information on the “Cylinder Cutout Remove.
Test” . Install new electronic unit injectors. Refer to Disassembly
and Assembly, Electronic Unit Injector - Install.
Repeat the automatic “Cylinder Cutout Test” . If the fault is
still present, remove the replacement electronic unit injector
and install the original electronic unit injector. Refer to Disas-
sembly and Assembly, Electronic Unit Injector - Remove and
Disassembly and Assembly, Electronic Unit Injector - Install.
Proceed to Test Step 5.

If the fault is cleared, return the unit to service.

Result: All injectors are OK.

Proceed to Test Step 5.

5. Engine Software and Electronic Control Module (ECM) Software updated Result The 190–10 does not recur after the software has
been updated.
A. Make sure that the latest flash file for the application is in-
stalled in the engine ECM. Return the unit to service.

B. Ensure that the ECM has been powered down after the Result The 190–10 code is still present after the software
ECM flash file has been updated. has been updated.

Proceed to Test Step 6.

6. Create an Electronic Service Tool Snapshot Snapshot saved Result: The electronic service tool snapshot was success-
fully saved.
A. Select “Snapshot Viewer” on the electronic service tool,
using menus: Information -> Snapshot -> Viewer Contact the DSN.

B. Select the diagnostic code and then click “View Graph” . Result: The electronic service tool snapshot was not suc-
cessfully saved.
C. Select the following parameter and then click OK.
Contact the DSN for guidance.
· Engine Speed

D. Select Save to "File to save" a Snapshot File (*.xml). This

file will contain all the data in the snapshot and not only the
data shown on the graph.
Note: The downloaded information will be required by the
Dealer Solutions Network (DSN) if diagnostic assistance is
needed.

i07621333 Use this procedure to troubleshoot the ether system

or use this procedure if a diagnostic code in Table
Ether Starting Aid - Test 159 is active or logged.

Before testing the ether injection system, remove

the ether canister from the system.

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Table 159
Diagnostic Trouble Codes for Ether Injection

J1939 Code Code Description Comments

626-5 Ether Injection Control Solenoid : Current Be- The Electronic Control Module (ECM) detects the following conditions:
low Normal
A low current condition in the output from the ECM to the solenoid for ether
injection

The ECM has been powered for at least 2 seconds.

If equipped, the warning lamp will come on. The ECM will log the diagnostic
code.
626-6 Ether Injection Control Solenoid : Current The Electronic Control Module (ECM) detects the following conditions:
Above Normal
A high current condition in the output from the ECM to the solenoid for ether
injection

The ECM has been powered for at least 2 seconds.

If equipped, the warning lamp will come on. The ECM will log the diagnostic
code.

If there is an active engine shutdown, the ether

injection system is disabled . The ether system will be
disabled if the glow plugs have been activated in the
last 5 minutes.
Activation of the ether starting aid is based on the
minimum temperature from one of the following
temperature sensors:
• Intake manifold temperature sensor

• Air intake temperature sensor

• Coolant temperature sensor
Refer to Illustration 39 .

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Illustration 39 g06396017

The following conditions must be met for the ether

injection system to be enabled:

• Ether injection is set to “Enabled” in the ECM

parameters
• The lower of the intake manifold air temperature,
the air inlet temperature, or the coolant
temperature is less than the activation point for
ether start aid. Refer to Illustration 39 .

• The maximum temperature of the intake manifold

air temperature sensor, the air inlet temperature
sensor, or the coolant temperature sensor is below
50° C (122° F).
During the following procedure, refer to the electrical
schematic for the application.
Complete the procedure in the order in which the
steps are listed.

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 M0095947-10 261
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Table 160
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose con- Result: The harness and wiring are OK.
nection or
A. Remove the electrical power from the ECM. damaged Proceed to Test Step 2.
wire
B. Thoroughly inspect the connector for the ether injection sole- Result: There is a fault in a connector or the wiring.
noid. Refer to Troubleshooting, “Electrical Connectors - Inspect”.
Repair: Repair any faulty connectors or replace the wiring har-
C. Perform a 30 N (6.7 lb) pull test on each of the wires in the ness. Ensure that all the seals are properly in place and en-
ether solenoid connector. sure that the connectors are correctly coupled.

D. Check the harness and the wiring for abrasion and for pinch Proceed to Test Step 4.
points.

Note: Do not disconnect the ECM connector at this stage. The

ECM can only be disconnected and reconnected 10 times before
damage to the harness connector may occur.

2. Check the Wiring Between the ECM and the Ether Control 10 VDC Result: The voltage measured 0 VDC.

The ether canister must be removed prior to performing this Repair: There is a problem in an electrical component be-
procedure. tween the ECM and the harness connector for the ether con-
trol. The problem may be inside an electrical connector. Make
A. Verify that the keyswitch is in the OFF position. the necessary repairs.

B. Remove the ether canister. Proceed to Test Step 3.

C. Disconnect the engine harness connector for the ether Result: The voltage measured greater than 10 VDC.
control.
The electrical components between the ECM and the harness
D. Connect a digital voltmeter across the two terminals on the en- connector for the ether control are OK.
gine harness connector for ether control.
Proceed to Test Step 3.
E. Turn the keyswitch to the ON position.

F. Measure the voltage across the terminals while the keyswitch

is turned ON.

3. Measure the Resistance of the Coil Inside the Ether 20 Ohms Result: The measured resistance was approximately 20
Control Ohms.

A. Verify that the ether control is not connected to the engine Proceed to Test Step 4.
harness.
Result: The measured resistance was not approximately 20
B. Measure the resistance of the coil inside the ether control. Ohms.

Repair: Replace the ether control.

Proceed to Test Step 4.

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Illustration 40 g03152796
Ether solenoid activation pin

Table 161
Troubleshooting Test Steps Values Results

4. Verify the Repair Plunger Result: The plunger moved up when the override was active.
movement
A. Activate the Ether Injection Override. Install the ether bottle and return the unit to service.

B. Verify that the plunger moved up when the override was If the procedure did not correct the issue, contact the Dealer
active. Solutions Network (DSN).

i08368851

Fuel Control - Test

This procedure covers the following diagnostic

codes:

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Table 162
Diagnostic Codes for the Fuel Control Valve

J1939 Code Code Description Comments

The Electronic Control Module (ECM) detects the following conditions:

Engine Fuel Injection Pump Fuel Low current in the output from the ECM to the fuel pump solenoid for 0.6 seconds.
1076–5 Control Valve : Current Below
Normal There are no active 168 diagnostic codes.

The warning lamp will come on. The diagnostic code will be logged.

The ECM detects the following conditions:

Engine Fuel Injection Pump Fuel High current in the output from the ECM to the fuel pump solenoid for 0.6 seconds.
1076–6 Control Valve : Current Above
Normal There are no active 168 diagnostic codes.

The warning lamp will come on. The diagnostic code will be logged.

Follow the troubleshooting procedure to identify the root cause of the fault.

The following background information is related

to this procedure:
Fuel Control Valve for the High-Pressure Fuel
Pump
The high-pressure fuel pump is equipped with a fuel
control valve. The fuel control valve precisely controls
the amount of fuel that enters the high-pressure fuel
pump.
The amount of fuel that is required is calculated by
the software that is contained in the ECM. The
solenoid in the fuel control valve is controlled by a
PWM signal from the ECM.

Illustration 41 g06371362
Schematic diagram for the fuel control valve

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Table 163
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection or Result: There is a fault in a connector or the wiring.
damaged wire
A. Thoroughly inspect the connector for the fuel control valve. Repair: Repair any faulty connectors or replace the wir-
Refer to Troubleshooting, “Electrical Connectors - Inspect” for ing harness. Ensure that all the seals are properly in
details. place and ensure that the connectors are correctly
coupled.
B. Thoroughly inspect the engine interface connector. Refer to
Troubleshooting, “Electrical Connectors - Inspect” for details. Use the electronic service tool to clear all logged diag-
nostic codes.
C. Check the harness for corrosion, abrasion, and pinch points Use the electronic service tool to verify that the repair
from the fuel control valve to the ECM. eliminates the fault.

Note: Do not disconnect the ECM connector at this stage. The Result: All connectors, pins, and sockets are correctly
ECM can only be disconnected and reconnected 10 times be- coupled and/or inserted. The harness is free of corro-
fore damage to the harness connector may occur. sion, abrasion, and pinch points.

Proceed to Test Step 2.

2. Check for Active Diagnostic Codes Diagnostic codes Result: A 1076-5 diagnostic code is active.

A. Turn the keyswitch to the OFF position. Proceed to Test Step 3.

B. Connect the electronic service tool to the diagnostic Result: A 1076–6 diagnostic code is active.
connector.
Proceed to Test Step 6.
C. Turn the keyswitch to the ON position.
Result: No diagnostic codes are active. There may be
E. Verify if any of the diagnostic codes that are listed in Table an intermittent fault.
162 are active.
Repair: Use the electronic service tool to perform a Wig-
F. Turn the keyswitch to the OFF position. gle Test.

If no faults are found, return the unit to service.

If the Wiggle Test identifies a fault, investigate the cause.

3. Create a Short Circuit at the Harness Connector for the Short circuit Result: A 1076–5 diagnostic code was active before in-
Fuel Control Valve stalling the jumper. A 1076–6 diagnostic code is active
when the jumper is installed - There is a fault in the fuel
A. Turn the keyswitch to the OFF position. control valve.

B. Disconnect the connector for the fuel control valve. Repair: Install a replacement fuel control valve. Refer to
Disassembly and Assembly, Flow Control Valve - Re-
C. Fabricate a jumper wire that is 150 mm (6 inch) long. move and Install.

D. Install the wire between the terminal 1 and terminal 2 on Use the electronic service tool to check that the repair
the harness connector for the fuel control valve to create a eliminates the fault.
short circuit.
Result: A 1076–5 diagnostic code is still active with the
E. Turn the keyswitch to the ON position. jumper installed.

F. Check for active diagnostic codes. Remove the jumper. Reconnect all connectors. Proceed
to Test Step 4.
G. Remove the jumper wire from the connector for the fuel
control valve.

(continued)

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(Table 163, contd)

Troubleshooting Test Steps Values Results

4. Create a Short Circuit at the Engine Interface Short circuit Result: A 1076–5 diagnostic code was active before in-
Connector stalling the jumper. A 1076–6 diagnostic code is active
when the jumper is installed - There is a fault in the en-
A. Turn the keyswitch to the OFF position. gine wiring harness.

B. Disconnect the engine interface connector. Repair: Repair the faulty wiring or replace the faulty
wiring.
C. Fabricate a jumper wire that is 150 mm (6 inch) long.
Use the electronic service tool to check that the repair
D. Install the wire between terminal 39 and terminal 40 on the eliminates the fault.
engine interface connector (ECM side).
Result: A 1076–5 diagnostic code is still active with the
E. Turn the keyswitch to the ON position. jumper installed.
F. Use the electronic service tool to check for an active 1076
diagnostic code. Remove the jumper. Reconnect all connectors. Proceed
Note: Diagnostic codes for all the engine sensors will be ac- to Test Step 5.
tive with the engine interface connector disconnected. Disre-
gard the other active diagnostic codes. Only look for an active
1076 code.

5. Check the Wiring to the ECM for an Open Circuit Less than 2 Ohms Result: At least one of the measured resistances is
greater than 2 Ohms. The fault is in the wiring connected
A. Turn the keyswitch to the OFF position. to the ECM connector.

B. Disconnect the P2 connector. Disconnect the connector for Repair: Repair the faulty wiring or replace the faulty
the fuel control valve. wiring.

C. Inspect the P2/J2 connectors for damage or corrosion. Result: The resistance is less than 2 Ohms.
Check for missing or bent pins on the ECM connector. Repair
or replace connectors as necessary. Refer to Troubleshooting, Contact the Dealer Solutions Network (DSN).
Electrical Connectors - Inspect for more information.

D. Perform a 30 N (6.7 lb) pull test on P2:72 and P2:94.

E. Use a suitable multimeter to measure the resistance be-

tween terminal 1 on the harness connector for the fuel control
valve and P2:94.
Use a suitable multimeter to measure the resistance between
terminal 2 on the harness connector for the fuel control valve
and P2:72.

6. Create an Open Circuit at the Fuel Control Valve Open circuit Result: A 1076–6 diagnostic code was active before dis-
connecting the fuel control valve. A 1076–5 diagnostic
A. Turn the keyswitch to the OFF position. code is active with the fuel control valve disconnected.
The fault is in the fuel control valve.
B. Disconnect the connector for the fuel control valve.
Repair: Install a replacement fuel control valve. Refer to
C. Turn the keyswitch to the ON position. Disassembly and Assembly, Flow Control Valve - Re-
move and Install.
D. Check for active diagnostic codes. Use the electronic service tool to check that the repair
eliminates the fault.

Result: A 1076–6 diagnostic code is still active with the

fuel control valve disconnected.

Proceed to Test Step 7.

(continued)

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(Table 163, contd)

Troubleshooting Test Steps Values Results

7. Create an Open Circuit at the Engine Interface Open circuit Result: A 1076–6 diagnostic code was active before dis-
Connector connecting the engine interface connector. A 1076–5 di-
agnostic code is active with the fuel control valve
A. Turn the keyswitch to the OFF position. disconnected. The fault is in the engine wiring harness.

B. Disconnect the engine interface connector. Repair: Repair the faulty wiring or replace the faulty
wiring.
C. Turn the keyswitch to the ON position. Use the electronic service tool to check that the repair
D. Use the electronic service tool to check for an active 1076 eliminates the fault.
diagnostic code.
Note: Diagnostic codes for all the engine sensors will be ac- Result: A 1076–6 diagnostic code is still active with the
tive with the engine interface connector disconnected. Disre- engine interface connector disconnected.
gard the other active diagnostic codes. Only look for an active
1076 code. Proceed to Test Step 7.

8. Check the Wiring to the ECM for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is
Ohm less than 1 k Ohm. The fault is in the wiring connected to
A. Turn the keyswitch to the OFF position. the ECM connector.

B. Disconnect the P2 connector. Disconnect the connector for Repair: Repair the faulty wiring or replace the faulty
the fuel control valve. wiring.

C. Inspect the P2/J2 connectors for damage or corrosion. Result: All resistance measurements are greater than 1
Check for missing or bent pins on the ECM connector. Repair k Ohm.
or replace connectors as necessary. Refer to Troubleshooting,
Electrical Connectors - Inspect for more information. Contact the Dealer Solutions Network (DSN).

D. Perform a 30 N (6.7 lb) pull test on the wire in P2:72 and

P2:94.

E. Use a suitable multimeter to measure the resistance be-

tween terminal 39 on the engine interface connector (ECM
side) and all other terminals on the engine interface connector.
Use a suitable multimeter to measure the resistance between
terminal 40 on the engine interface connector (ECM side) and
all other terminals on the engine interface connector.

i07979580

Fuel Transfer Pump - Test

Use this procedure to troubleshoot the relay for the

Electric Priming Pump (EPP). Use this procedure if
there is a suspected electrical fault with the EPP.
This procedure covers the following diagnostic
codes:

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Table 164
Diagnostic Codes for the EPP Relay

J1939 Code Code Description Comments

The Electronic Control Module (ECM) detects a low current condition in
the EPP relay circuit.
Engine Electric Lift Pump for Engine Fuel Supply :
1075-5 The warning light will come on. The diagnostic code will be logged.
Current Below Normal
The ECM is unable to activate the relay for the EPP. The EPP will not op-
erate or the EPP will operate all the time. The engine will not operate.

The ECM detects a high current condition in the EPP relay circuit.

There is a high current condition in the EPP relay circuit for more than 2
Engine Electric Lift Pump for Engine Fuel Supply : seconds.
1075-6
Current Above Normal
The warning light will come on. The diagnostic code will be logged.
The ECM is unable to activate the relay for the EPP. The EPP will not op-
erate or the EPP will operate all the time. The engine will not operate.

The following background information is related

to this procedure:
The EPP is used to provide positive fuel pressure to
the high-pressure fuel pump. When the keyswitch is
turned to the ON position, the ECM will activate the
EPP. If the engine is not running, the ECM will
deactivate the EPP after 2 minutes.
Not all engines are equipped with an EPP. Ensure
that the ECM parameters for the EPP are correctly
configured for the hardware equipped.
There are three different installation configurations:
Engines equipped with a single fuel filter and a
manual fuel priming pump An EPP is not installed
in this system. Set the “Engine Fuel Lift Pump
Installation Status” to “Not Installed” .
Engines equipped with a single fuel filter and an
EPP Set the “Engine Fuel Lift Pump Installation
Status” to “Installed” . Set the “Periodic Fuel Priming
Enable Status” to “Enabled” .
Engines equipped with two fuel filters and an
EPP Set the “Engine Fuel Lift Pump Installation
Status” to “Installed” . Set the “Periodic Fuel Priming
Enable Status” to “Disabled” .
Refer to Systems Operation, Testing and Adjusting
for more information on the different types of fuel
system installation configurations.

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Illustration 42 g06497975
Schematic for the Electric Priming Pump (EPP) relay

During the following procedure, refer to the electrical

schematic for the application.
Complete the procedure in the order in which the
steps are listed.

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 M0095947-10 269
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Table 165
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection Result: There is a fault in a connector or the wiring. A fuse
or damaged wire is blown.
A. Turn the keyswitch to the OFF position.
Repair: Repair any faulty connectors or replace the wiring
B. Check the fuses. harness. Ensure that all the seals are properly in place and
ensure that the connectors are correctly coupled. Replace
C. Thoroughly inspect the connectors between the EPP relay blown fuses.
and the engine ECM. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details. Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.
D. Check the harness and wiring for abrasion and for pinch
points from the EPP to the ECM and from the EPP relay to the Result: All connectors, pins, and sockets are correctly
battery. coupled and/or inserted. The harness is free of corrosion,
abrasion, and pinch points.
Note: Do not disconnect the ECM connector at this stage. The
ECM can only be disconnected and reconnected 10 times be- Proceed to Test Step 2.
fore damage to the harness connector may occur.

2. Check for Active Diagnostic Codes Diagnostic codes Result: Diagnostic code 1075-5 is active or recently
logged.
A. Connect the electronic service tool to the diagnostic
connector. Proceed to Test Step 3.

B. Turn the keyswitch to the ON position. Do not start the Result: Diagnostic code 1075-6 is active or recently
engine. logged.

C. Make a note of any active diagnostic codes. Proceed to Test Step 5.

D. Wait for at least 2 minutes for the Electric Priming Pump

(EPP) to deactivate. Make a note of any active diagnostic
codes.

3. Create a Short Circuit at the EPP Relay Open circuit Result: A 1075-6 diagnostic code was active with the jump-
er installed.
A. Turn the keyswitch to the OFF position.
Repair: Install a replacement EPP relay.
B. Disconnect the harness connector for the EPP relay.
Reconnect the connector for the EPP relay.
C. Fabricate a jumper wire that is 150 mm (6 inch) long.
Turn the keyswitch to the ON position. Do not start the en-
D. Use the jumper wire to connect Test Point 1 to Test Point 2 gine. Check for active diagnostic codes.
on the harness connector for the EPP relay. Refer to Illustra-
tion 42 . Wait for at least 2 minutes for the EPP to deactivate. Check
for active diagnostic codes.
E. Turn the keyswitch to the ON position. Do not start the
engine. Confirm that the fault has been eliminated.

F. Use the electronic service tool to check for an active 1075-6 Result: A 1075-5 diagnostic code is still active with the
diagnostic code. jumper installed. There is a fault in the wiring or the ECM.

G. Wait for at least 2 minutes for the EPP to deactivate. Check Proceed to Test Step 4.
for an active 1075-5 diagnostic code.

H. Turn the keyswitch to the OFF position.

I. Remove the jumper. Leave the connector for the EPP

disconnected.

(continued)

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(Table 165, contd)

Troubleshooting Test Steps Values Results

4. Check the Wiring Between the ECM and the EPP Relay Less than 2 Ohms Result: The resistance measurement is greater than 2
for an Open Circuit Ohms.

A. Turn the keyswitch to the OFF position. Repair: The fault is in the wiring between the EPP relay
and the ECM.
B. Disconnect the EPP relay. Disconnect the J1 connector Repair the faulty wiring or replace the faulty wiring. Use the
from the ECM. electronic service tool to clear all logged diagnostic codes
C. Inspect the P1/J1 connectors for damage or corrosion. Re- and verify that the repair eliminates the fault.
fer to Troubleshooting, Electrical Connectors - Inspect for
more information. Result: The resistance measurement is less than 2 Ohms.

D. Perform a 30 N (6.7 lb) pull test on P1:15. Contact the Dealer Solutions Network (DSN).

E. Measure the resistance between P1:15 and Test Point 1 on

the harness connector for the relay.

5. Create an Open Circuit at the Relay Short circuit Result: A 1075-5 diagnostic code is active. There are no
faults in the wiring for the EPP.
A. Turn the keyswitch to the OFF position.
Repair: Install a replacement relay.
B. Disconnect the harness connector for the EPP relay.
Turn the keyswitch to the ON position. Do not start the
C. Turn the keyswitch to the ON position. Do not start the engine.
engine.
Wait for at least 2 minutes for the EPP to deactivate. Check
Wait for at least 2 minutes for the EPP to deactivate. for active diagnostic codes.

D. Use the electronic service tool to check for an active 1075- Confirm that the fault has been eliminated.
6 diagnostic code.
Result: A 1075-6 diagnostic code is still active. There is a
E. Turn the keyswitch to the OFF position. fault in the wiring or the ECM.

Proceed to Test Step 6.

6. Check the Wiring Between the Relay and the ECM for a Greater than 1k Result: At least one of the resistance measurements is less
Short Circuit Ohm than 1k Ohm. The fault is in the wiring between the EPP re-
lay and the ECM.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty
B. Disconnect the P1 connector. harness.

C. Inspect the P1/J1 connector. Refer to Troubleshooting, Turn the keyswitch to the ON position. Do not start the en-
“Electrical Connectors - Inspect”. gine. Check for active diagnostic codes.

D. Perform a 30 N (6.7 lb) pull test on P1:15. Wait for at least 2 minutes for the EPP to deactivate. Check
for active diagnostic codes.
E. Disconnect the connector for the Electric Priming Pump
(EPP) relay. Confirm that the fault has been eliminated.

F. Measure the resistance between P1:15 and all other pins on Result: All resistance measurements are greater than 1k
the P1 connector. Ohm.

Contact the Dealer Solutions Network (DSN).

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i07528510

Glow Plug Starting Aid - Test

This procedure covers the following diagnostic

codes:
Use this procedure if there is a suspected fault in the
glow plug start aid circuit or the glow plugs.
Table 166
Diagnostic Trouble Codes For The Glow Plug Starting Aid

J1939 Code Code Description Comments

The Electronic Control Module (ECM) detects a low current condition in the glow plug
start aid relay circuit.
Engine Glow Plug Relay : Current
676-5
Below Normal The ECM is unable to activate the relay for the glow plug starting aid. The glow plugs will
not operate. The engine may be difficult to start in cold temperatures and the exhaust
may emit white smoke.

The Electronic Control Module (ECM) detects a high current condition in the glow plug
start aid relay circuit
Engine Glow Plug Relay : Current
676-6
Above Normal The ECM is unable to activate the relay for the glow plug starting aid. The glow plugs will
not operate or the glow plugs will operate all the time. The engine may be difficult to start
in cold temperatures and the exhaust may emit white smoke.

Follow the troubleshooting procedure to identify the root cause of the fault.

The following background information is related When glow plugs need to be activated prior to
to this procedure: starting, a lamp will indicate that the operator needs
to “Wait to Start” . Starting aids may be used during
The starting aid is used to improve the engine the cranking of the engine. Starting aids may be used
starting when the engine is cold. With the keyswitch if the engine has previously been started. The “Wait
in the ON position, the ECM monitors the following to Start” lamp will not be active in these conditions.
parameters to decide if the glow plugs need to be
switched ON: Electronic Service Tool Test Aid
• Coolant temperature The electronic service tool includes the test “Glow
Plug Start Aid Override Test” . This test will assist the
• Intake manifold air temperature analysis of the cold starting aid.

• Air inlet temperature Overview of the Glow Plug Start Aid Override
Test
If the glow plugs are required, then the ECM will
activate the starting aid relay for a controlled period. This glow plug start aid override test switches on the
While the glow plug start aid relay is activated, the cold starting aid when the engine is not running. The
glow plug start aid relay will supply power to the glow glow plug start aid override test aids the analysis of
plugs. If a “Wait To Start” lamp is installed, then this the circuit for the glow plug start aid relay.
lamp will be illuminated to indicate the “Wait To Start”
period.

Note: The glow plugs will be disabled if the ether

start aid (if equipped) has been activated less than 5
minutes ago.
“ Wait to Start Lamp””
This feature may be included as an option.

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Illustration 43 g06351045
Schematic for the glow plug starting aid circuit
Not all connectors are shown. Refer to the appropriate Electrical Schematic.

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 M0095947-10 273
Circuit Tests

Table 167
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection Result: There is a fault in a connector or the wiring.
or damaged wire
A. Check that the fuses are not blown. Repair: Repair any faulty connectors or replace the wiring
harness. Ensure that all the seals are properly in place and
B. Inspect the terminals on the glow plug start aid relay and ensure that the connectors are correctly coupled.
then inspect the connector on the flying lead from the relay. Use the electronic service tool to clear all logged diagnostic
Refer to Troubleshooting, “Electrical Connectors - Inspect” for codes and verify that the repair eliminates the fault.
details.
Result: All connectors, pins, and sockets are correctly
C. Inspect the bus bar for the glow plugs. Ensure that the nuts coupled and/or inserted. The harness is free of corrosion,
that secure the bus bar to each glow plug are tightened to a abrasion, and pinch points. The fuses are not blown. The
torque of 2 N·m (17 lb in). Ensure that the bus bar is not bus bar is secured to the glow plugs and not shorted to
shorted to the engine. ground.

D. Check the harness for abrasion and pinch points from the Proceed to Test Step 2.
glow plugs back to the ECM.

Note: Do not disconnect the ECM connector at this stage. The

ECM can only be disconnected and reconnected 10 times be-
fore damage to the harness connector may occur.

2. Check for Active Diagnostic Codes Diagnostic codes Result: No diagnostic codes are present.

A. Connect the electronic service tool to the diagnostic There may be an intermittent fault in an electrical compo-
connector. nent between the ECM and the glow plugs. The problem
may be inside an electrical connector. Refer to Trouble-
B. Turn the keyswitch to the ON position. shooting, “Electrical Connector - Inspect” to identify inter-
Note: Do not start the engine. mittent faults.

C. Use the electronic service tool to select the “Glow Plug There may be a fault in the glow plug switched power cir-
Start Aid Override Test” to turn on the power for the glow cuit. The ECM does not monitor the status of this condition.
plugs. Proceed to Test Step 7 to test this circuit.

D. Check for an active or recently logged 676 diagnostic code. Result: Diagnostic code 676-5 is active or recently logged.

Proceed to Test Step 3.

Result: Diagnostic code 676-6 is active or recently logged.

Proceed to Test Step 5.

(continued)

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(Table 167, contd)

Troubleshooting Test Steps Values Results

3. Create a Short Circuit at the Relay Connector Diagnostic code Result: A 676-6 diagnostic code is active with the jumper
installed.
A. Turn the keyswitch to the OFF position.
Install a replacement glow plug relay.
B. Remove the glow plug start aid relay.
Use the electronic service tool to clear all logged diagnostic
C. Fabricate a jumper wire. Install the jumper wire between codes and verify that the repair eliminates the fault.
Test Point 1 and Test Point 2 on the harness connector for the
glow plug relay. Refer to Illustration 43 . Refer to the appropri- Result: The 676-5 diagnostic code is still active.
ate Electrical Schematic.
Proceed to Test Step 4.
D. Turn the keyswitch to the ON position.

E. Use the electronic service tool to select the “Glow Plug Start
Aid Override Test” to turn on the power for the glow plugs.

F. Use the electronic service tool to check for active diagnostic

codes. Wait at least 30 seconds for activation of the diagnostic
codes.

G. Turn the keyswitch to the OFF position and remove the

jumper wire.

4. Check the Wiring Between the ECM and the Relay for Less than 2 Ohms Result: At least one of the resistance measurements is
an Open Circuit greater than 2 Ohms - the fault is in the wiring for the relay
control circuit.
A. Verify that the keyswitch is in the OFF position.
Repair: Repair the faulty wiring or replace the faulty wiring.
B. Disconnect the P2 connector from the ECM.
Result: The resistance measurement is less than 2 Ohms.
C. Inspect the P2 connector. Refer to Troubleshooting, “Elec-
trical Connectors - Inspect” for details. Contact the Dealer Solutions Network (DSN).

D. Perform a 30 N (6.7 lb) on P2:105.

E. Measure the resistance between Test Point 1 on the har-

ness connector for the relay and a suitable ground.

F. Measure the resistance between Test Point 2 on the har-

ness connector for the relay and P2:105.
Refer to the appropriate Electrical Schematic.

5. Create an Open Circuit at the Relay Diagnostic codes Result:A 676-5 diagnostic code is active with the relay
disconnected.
A. Turn the keyswitch to the OFF position.
Repair: Install a replacement glow plug start aid relay.
B. Disconnect the glow plug start aid relay. Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.
C. Use the electronic service tool to select the “Glow Plug
Start Aid Override Test” to turn on the power for the glow Result: The 676-6 diagnostic code is still active with the re-
plugs. lay disconnected.

D. Use the electronic service tool to check for active diagnostic Proceed to Test Step 6.
codes. Wait at least 30 seconds for activation of the diagnostic
codes.

(continued)

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(Table 167, contd)

Troubleshooting Test Steps Values Results

6. Check the Wiring Between the Relay and the ECM for a Greater than 1 k Result: At least one of the resistance measurements is less
Short Circuit Ohm than 1 k Ohm. There is a short in the wiring between the re-
lay and the ECM.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty wiring.
B. Disconnect the P2 connector from the ECM. Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.
C. Inspect the P2 connector. Refer to Troubleshooting, “Elec-
trical Connectors - Inspect” for details. Result: All resistance measurements are greater than 1 k
Ohm.
D. Perform a 30 N (6.7 lb) on P2:105.
C. Use a suitable multimeter to measure the resistance be- Contact the Dealer Solutions Network (DSN).
tween P2:105 and all other terminals on the P2 connector.

7. Check the Operation of the Glow Plugs Approximately 28 Result: The reading on the clamp on ammeter near the ex-
Amps for a 12 pected reading.
A. Place a suitable clamp-on ammeter on the power supply VDC system.
wire. Approximately 10 The glow plugs are operating correctly.
Amps for a 24 Return the engine to service.
B. Use the electronic service tool to select the “Glow Plug VDC system.
Start Aid Override Test” to turn on the power for the glow Result: The reading on the clamp on ammeter is between
plugs. zero and the expected reading.

C. Wait for 20 seconds and then note the reading on the Proceed to Test Step 8.
clamp-on ammeter.
Result: The reading on the clamp on ammeter is zero.

Proceed to Test Step 9.

8. Test the Continuity of the Glow Plugs One or more glow Result: One or more of the glow plugs do not display
plugs do not have continuity.
A. Disconnect the power supply and remove the bus bar from continuity.
the glow plugs. Repair: Replace any glow plugs that do not show
continuity.
B. Use a suitable digital multimeter to check continuity (resist- Use the electronic service tool to clear all logged diagnostic
ance). Turn the audible signal on the digital multimeter ON. codes and verify that the repair eliminates the fault.

C. Place one probe on the connection for one of the glow Result: All glow plugs display continuity.
plugs and the other probe to a suitable ground. The digital
multimeter should make an audible sound. Repeat this procedure from Test Step 1.

D. Repeat the continuity check on the remaining glow plugs.

9. Check the Fuse Blown fuse Result: The fuse is blown - there is a short in the power cir-
cuit for the glow plugs.
A. Turn the battery disconnect switch to the OFF position.
Check the wiring between the batteries and the glow plug
B. Check the fuse for the glow plug start aid relay. Refer to the relay for a short circuit. Refer to the appropriate Electrical
appropriate Electrical Schematic. Schematic. Make any necessary repairs.
Replace the blown fuse.

Result: The fuse is not blown.

Proceed to Test Step 10.

(continued)

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(Table 167, contd)

Troubleshooting Test Steps Values Results

10. Check the Power Supply to the Relay Connector Battery voltage Result: There is no battery voltage at Test Point A on the
harness connector.
A. Disconnect the connector for the glow plug relay.
Repair: Check all wiring between the batteries and the glow
B. Measure the voltage between Test Point A on the harness plug relay. Make any necessary repairs.
connector for the relay and a suitable ground.
Refer to Illustration 43 and the appropriate Electrical Result: Battery voltage is present at Test Point A on the
Schematic. harness connector.

Proceed to Test Step 11.

11. Check the Power Supply to the Glow Plugs Battery voltage Result: There is no battery voltage at the power supply wir-
ing to the bus bar.
A. Disconnect the power supply for the bus bar. Ensure that
the glow plug relay is connected. Repair: Check all wiring between the bus bar and the glow
plug relay. Make any necessary repairs.
B. Turn the keyswitch to the ON position.
If the wiring is OK, replace the glow plug relay.
C. Use the electronic service tool to select the “Glow Plug
Start Aid Override Test” to turn on the power for the glow Result: Battery voltage is present at the power supply wir-
plugs. ing to the bus bar.

D. Measure the voltage between the power supply wiring for The glow plug circuit appears to be operating correctly.
the bus bar and engine ground.
Return the engine to service.

i07816933

Idle Validation - Test

This procedure covers the following diagnostic

codes:
Table 168
Diagnostic Trouble Codes for the Idle Validation Switches

J1939 Code Code Description Comments

Accelerator Pedal #1 Low Idle
558-2 Switch : Erratic, Intermittent, or The Electronic Control Module (ECM) detects the following condition:
Incorrect
The signal from the Idle Validation Switch (IVS) is invalid.
Accelerator Pedal #2 Low Idle
2970-2 Switch : Erratic, Intermittent, or If equipped, the warning light will come on. The ECM will log the diagnostic code.
Incorrect
Follow the troubleshooting procedure to identify the root cause of the fault.

If the application is equipped with two throttles, the • If the engine speed is higher than the speed in
engine will use the second throttle until the fault is limp home mode, the engine will decelerate to limp
repaired. home mode.
If a second throttle is not installed or if the second • If the engine speed is lower than the speed in limp
throttle has a fault, the following conditions will occur: home mode, the engine speed will remain at the
• The engine will default to limp home mode. current speed.

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• The engine will remain at this speed while the

diagnostic code remains active.

• All inputs from the faulty throttle are ignored by the

ECM until the fault is repaired.
• All inputs from the repaired throttle will be ignored
by the ECM until the keyswitch has been cycled.
The IVS may be installed. The IVS is required for
mobile applications with an analog throttle installed.
The IVS is part of the throttle position sensor. The
IVS is CLOSED when the low idle is set.
The configuration parameters for the throttle and for
the IVS thresholds are programmed into the ECM.
Use the electronic service tool to display the
configuration parameters for the throttle and for the
IVS.
If the IVS operates outside of the programmed range,
then the engine speed may not respond to changes
in the throttle position.
The electronic service tool may be used for the
following:
• If necessary, reset the IVS threshold for an
existing IVS.
• If necessary, view the IVS change point and reset
the IVS thresholds when a new throttle assembly
is installed.

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Illustration 44 g06382644
Schematic of the IVS circuit
Not all connectors are shown. Refer to the appropriate Electrical Schematic

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the throttle connectors and
the ECM connectors.

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 M0095947-10 279
Circuit Tests

Table 169
Troubleshooting Test Steps Values Results

1. Check for Active Diagnostic Codes and/or Recently Diagnostic codes Result: No diagnostic codes are active - the problem
Logged Diagnostic Codes may have been intermittent.

A. Connect the electronic service tool to the diagnostic Repair: Carefully inspect the connectors and wiring.
connector. Refer to Troubleshooting, “Electrical Connectors -
Inspect”.
B. Turn the keyswitch to the ON position.
Result: One of the diagnostic codes listed in Table 168
C. Monitor the active diagnostic code screen on the electronic is active or recently logged.
service tool. Check and record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic codes Proceed to Test Step 2.
to become active.
Note: A diagnostic code that is logged several times is an indi-
cation of an intermittent problem. Most intermittent problems
are a poor connection in a connector.

2. Check the Operation of the IVS IVS status change Result: The IVS state changes from CLOSED (ON) to
OPEN (OFF)
A. Connect the electronic service tool to the diagnostic
connector. Proceed to Test Step 3.

B. Turn the keyswitch to the ON position. Result: The IVS state does not change.
Note: Do not start the engine.
Proceed to Test Step 4.
C. Use the electronic service tool to check the current “Throttle
Configuration” .

D. Select the “SERVICE” option from the drop-down menu of

the electronic service tool.

E. Select the “Throttle Configuration” option on the electronic

service tool. Select the appropriate “Throttle Configuration”
summary from the menu on the left of the screen. The IVS win-
dow for the throttle will indicate “YES” if an IVS is installed.

F. Select the “Throttle status” function on the electronic service

tool. Select “Status” function and then select “Throttles”
function.

G. The throttle is set in the low idle position.

H. Operate the throttle slowly. The IVS status should change

from CLOSED (ON) to OPEN (OFF).

(continued)

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(Table 169, contd)

Troubleshooting Test Steps Values Results

3. Check the IVS Threshold IVS operates within Result: The IVS switch operates within the “Idle Valida-
threshold. tion Min OFF Threshold” and the “Idle Validation Max
A. Connect the electronic service tool to the diagnostic ON Threshold” parameters.
connector.
The IVS is operating correctly.
B. Turn the keyswitch to the ON position. Return the engine to service.

C. Use the electronic service tool to check the current “Throttle Result: The IVS switch cannot operate within the “Idle
Configuration” . Validation Min OFF Threshold” and the “Idle Validation
Max ON Threshold” parameters.
D. Select the “SERVICE” option from the drop-down menu of
the electronic service tool. Proceed to Test Step 9.

E. Select the “Throttle Configuration” option on the electronic

service tool. Select the appropriate “Throttle Configuration”
summary from the menu on the left of the screen. The IVS win-
dow for the throttle will indicate “YES” if an IVS is installed.
Make a note of the “Idle Validation Min OFF Threshold” param-
eters that are displayed in the “Throttle Configuration” menu of
the electronic service tool. Make a note of the “Idle Validation
Max ON Threshold” parameters that are displayed in the
“Throttle Configuration” menu of the electronic service tool.

F. To select the “Throttle status” function on the electronic serv-

ice tool, select “Status” function and then select “Throttles”
function.

G. The throttle is set in the low idle position.

H. Operate the throttle slowly. The IVS status should change

from CLOSED (ON) to OPEN (OFF).

4. Inspect Electrical Connectors and the Harness Loose connection or Result: Faults found in harness or connectors.
damaged wire
A. Inspect the P1/J1 and P2/J2 connectors, the harness and all Repair: Repair the connectors or the harness and/or re-
the connectors for the IVS. Refer to Troubleshooting, “Electrical place the connectors or the harness. Ensure that all the
Connectors - Inspect” for details. seals are correctly in place and ensure that the connec-
tors are correctly connected.
B. Perform a 30 N (6.7 lb) pull test on each of the wires in the Use the electronic service tool to clear all logged diag-
ECM connector that are associated with the suspect idle valida- nostic codes and then verify that the repair eliminates
tion switch. the fault.

C. Check the harness for abrasion and pinch points from the Result: No harness or connector faults found.
throttle switch to the ECM.
Proceed to Test Step 5.

(continued)

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 M0095947-10 281
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(Table 169, contd)

Troubleshooting Test Steps Values Results
IVS state on with
5. Check the Location of the Fault jumper installed. Result: With the jumper wire connected, the electronic
service tool displays the IVS state in the ON position on
A. Disconnect the IVS harness connector. IVS state off with the throttle status screen. With the jumper wire discon-
jumper removed. nected, the electronic service tool displays the IVS state
B. Fabricate a jumper wire. in the OFF position on the throttle status screen.

C. Turn the keyswitch to the ON position. Proceed to Test Step 8.

D. Install a jumper wire between the IVS connections on the Result: The IVS status that is displayed on the elec-
harness. Use the electronic service tool to check for diagnostic tronic service tool does not change with the jumper wire
codes. either removed or installed.

E. Remove the jumper wire that is between the IVS connections Proceed to Test Step 6.
on the harness. Use the electronic service tool to check for di-
agnostic codes.

6. Check the Wiring for an Open Circuit Less than 2 Ohms Result: One or more of the measured resistances is
greater than 2 Ohms. There is an open circuit in the
A. Disconnect the IVS harness connector. wiring.

B. Disconnect the P1 connector. Repair: Repair the faulty wiring or replace the faulty
wiring.
C. If the fault is on IVS1, use a multimeter to check the resist- Use the electronic service tool to clear all logged diag-
ance between the IVS1 input terminal on the IVS harness con- nostic codes and verify that the repair eliminates the
nector and P1:31. fault.

D. If the fault is on IVS2, use a multimeter to check the resist- Result: The measured resistance in all wires is less
ance between the IVS2 input terminal on the IVS harness con- than 2 Ohms.
nector and P1:30.
Proceed to Test Step 7.
E. Use a multimeter to check the resistance between the IVS
output terminal on the applicable IVS harness connector and
P2:47.

7. Check the Wiring for a Short Circuit Greater than 1 k Result: The measured resistance is less than 1 k Ohm.
Ohm There is a short circuit in the wiring.
A. Disconnect the P1 connector.
Repair: Repair the faulty wiring or replace the faulty
B. Disconnect both IVS harness connectors. wiring.
Use the electronic service tool to clear all logged diag-
C. Use a multimeter to check the resistance between the sus- nostic codes and verify that the repair eliminates the
pect IVS input terminal and a suitable ground. fault.

Result: All resistance measurements are greater than 1

k Ohm.

Contact the Dealer Solutions Network (DSN).

(continued)

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 282 M0095947-10
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(Table 169, contd)

Troubleshooting Test Steps Values Results

8. Check the IVS Calibration The IVS operates Result: The IVS operates within the “Idle Validation Min
within the OFF Threshold” and the “Idle Validation Max ON
A. Connect the electronic service tool to the diagnostic thresholds. Threshold” values.
connector.
The IVS is operating correctly.
B. Turn the keyswitch to the ON position. Return the engine to service.

C. Select the “Throttle Configuration” option on the electronic Result: The IVS does not operate within the “Idle Vali-
service tool. Select the appropriate “Throttle Configuration” dation Min OFF Threshold” and the “Idle Validation Max
summary from the menu on the left of the screen. The IVS win- ON Threshold” values.
dow for the throttle will indicate “YES” if an IVS is installed.
Make a note of the “Idle Validation Min OFF Threshold” param- Proceed to Test Step 9.
eters that are displayed in the “Throttle Configuration” menu of
the electronic service tool. Make a note of the “Idle Validation
Max ON Threshold” parameters that are displayed in the
“Throttle Configuration” menu of the electronic service tool.

D. Select the “Throttle status” function on the electronic service

tool. Select “Status” function and then select “Throttles”
function.

E. Set the throttle to low idle.

F. Operate the throttle slowly toward high idle. The raw percent-
age values for the throttle that are shown on the electronic serv-
ice tool should increase and the IVS status should change from
CLOSED (ON) to OPEN (OFF) position. Make a note of the raw
reading for the throttle when the IVS reading changes from the
CLOSED position to the OPEN position. Repeat this step to ob-
tain accurate raw percentage values for the throttle. The noted
value should be within the previously noted “Idle Validation Min
OFF Threshold” and “Idle Validation Max ON Threshold” limits.

G. The throttle is set to the full throttle position or the high idle
position.

H. Operate the throttle slowly toward low idle. The raw percent-
age values for the throttle that are shown on the electronic serv-
ice tool should decrease and the IVS status should change
from OPEN (OFF) to CLOSED (ON) position. Make a note of
the raw reading for the throttle when the IVS reading changes
from the OPEN position to the CLOSED position. Repeat this
step to obtain accurate raw percentage values for the throttle.
The noted value should be within the previously noted “Idle Val-
idation Min OFF Threshold” and “Idle Validation Max ON
Threshold” limits.

9. Use the Electronic Service Tool to Reset the IVS Thresh- The fault is cleared. Result: The fault is cleared after programming the new
old Limits calculated values.

The electronic service tool can be used to change the following Use the electronic service tool to clear all logged diag-
parameters to suit the type of throttle that is installed: nostic codes and verify that the repair eliminates the
· Idle Validation Min OFF Threshold fault.
· Idle Validation Max ON Threshold Return the engine to service.
Note: The limits are shown in the “Throttle Configuration”
screen which is located in the “Service” menu. Result: The fault is not cleared.

Contact the Dealer Solutions Network (DSN).

(continued)

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 M0095947-10 283
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(Table 169, contd)

Troubleshooting Test Steps Values Results
A. Refer to Test Step 8. “Check the IVS Calibration”. Record
the raw value of the throttle signal when the idle validation
switch changes from the CLOSED position to the OPEN
position.
Note: The default value for the “Idle Validation Min OFF
Threshold” is 21%. The lowest value that should be set is 5%.
The default value for the “Idle Validation Max ON Threshold” is
25%. The maximum value that is expected is 28%.

B. Set the “Idle Validation Min OFF Threshold” to 3% below the

raw value that was previously recorded.

C. Set the “Idle Validation Max ON Threshold” to 3% above the

raw value.

D. Enter the new threshold limits into the electronic service tool.
Click “Submit” on the electronic service tool screen.

E. Turn the keyswitch to the OFF position and wait at least 5

seconds. Turn the keyswitch to the ON position.

F. Repeat Test Step 8. Check that the IVS operates within the
newly set threshold limits.

i07979677 Note: The diagnostic aid that switches the lamps is

contained in the “Override” section in the
Indicator Lamp - Test “diagnostics” menu of the electronic service tool.

Use this procedure under the following

circumstances:
• The lamps are not receiving battery voltage.

• The lamps are not operating correctly.

The following diagnostic lamps are available:
• Wait to start lamp
• Low oil pressure lamp

• Emissions system failure lamp

• Wait to disconnect lamp

• Diesel Particulate Filter (DPF) lamp

• Low DEF level lamp

• DEF quality lamp

• Shutdown lamp

• Warning lamp
• Engine running lamp
The electronic service tool can be used as a
diagnostic aid to switch the individual lamps ON and
OFF.

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 284 M0095947-10
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Illustration 45 g06498074
Typical schematic of the circuit for the indicator lamps

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the indicator lamps and the
ECM connectors.

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 M0095947-10 285
Circuit Tests

Table 170
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection Result: There is a fault in a connector or the wiring.
or damaged wire
A. Turn the keyswitch to the OFF position. Repair: Repair any faulty connectors or replace the wiring
harness. Ensure that all the seals are properly in place and
B. Check that the fuses are not blown. ensure that the connectors are correctly coupled.
Replace any blown fuses.
C. Thoroughly inspect the P1/P2 connector and the lamp con- Use the electronic service tool to verify that the repair elimi-
nections. Refer to Troubleshooting, “Electrical Connectors - In- nates the fault.
spect” for details.
Result: All connectors, pins, and sockets are correctly
D. Perform a 30 N (6.7 lb) pull test on each of the wires in the coupled and/or inserted. The harness is free of corrosion,
P1/P2 connector that are associated with the indicator lamps. abrasion, and pinch points. The fuses are not blown.

E. Check the harness for abrasions and for pinch points from Proceed to Test Step 2.
the battery to the ECM.

2. Inspect the Lamp Less than 2000 Result: The lamp has greater than 2000 Ohms resistance.
Ohms
A. Disconnect the lamp from the harness. Inspect the lamp to Repair: Replace the suspect lamp.
determine if the lamp has failed.
Use the electronic service tool to verify that the repair elimi-
B. Measure the resistance across the two terminals of the nates the fault.
lamp.
Result: The lamp has less than 2000 Ohms resistance.

Proceed to Test Step 3.

3. Measure the Input Voltage to the Lamp at the Lamp At least 10 VDC Result: The voltage is not within the expected range - the
Socket for a 12 V system. fault is in the battery supply wiring to the lamp.
At least 22 VDC
A. Turn the keyswitch to the ON position. for a 24 V system. Repair: Repair the faulty wiring or replace the faulty wiring.
Use the electronic service tool to verify that the repair elimi-
B. Use the electronic service tool to select the “override” func- nates the fault.
tion to switch individual lamps ON and OFF.
Note: The “Override” function is contained in the “Diagnostics” Result: The voltage is within the expected range.
menu of the electronic service tool.
Proceed to Test Step 4.
C. Measure the voltage at the lamp socket.

(continued)

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 286 M0095947-10
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(Table 170, contd)

Troubleshooting Test Steps Values Results

4. Check the Wiring for an Open Circuit Less than 2 Ohms Result: The measured resistance is greater than 2 Ohms -
the fault is in the wiring between the lamp holder and the
A. Turn the keyswitch to the OFF position. ECM.

B. Disconnect the P1 connector. Repair: Repair the faulty wiring or replace the faulty wiring.

C. Remove the bulb from the suspect lamp. Use the electronic service tool to verify that the repair elimi-
nates the fault.
D. Use a multimeter to measure the resistance between the
ground connection on the lamp holder and the applicable ter- Result: The measured resistance is less than 2 Ohms.
minal on the P1 connector.
Proceed to Test Step 5.

5. Check the Wiring for a Short Circuit Greater than 1k Result: The measured resistance is less than 1k Ohm.
Ohm There is a short in the wiring between the lamp holder and
A. Disconnect the P1 connector. Disconnect the suspect lamp. the ECM.

B. Use a multimeter to check the resistance between the lamp Repair: Repair the faulty wiring or replace the faulty wiring.
socket and a suitable ground. Use the electronic service tool to verify that the repair elimi-
nates the fault.

Result: The measured resistance is greater than 1k Ohm.

Contact the Dealer Solutions Network (DSN).

i07573309

Injector Data Incorrect - Test

This procedure covers the following codes:

Table 171
Diagnostic Codes for Injector Data Incorrect

J1939 Code Code Description Comments

651-2 Engine Injector Cylinder #01 : Erratic, Intermittent, or Incorrect

652-2 Engine Injector Cylinder #02 : Erratic, Intermittent, or Incorrect The Electronic Control Module (ECM) detects an injector code
that is incorrect for the engine.
653-2 Engine Injector Cylinder #03 : Erratic, Intermittent, or Incorrect The warning lamp will come on.

654-2 Engine Injector Cylinder #04 : Erratic, Intermittent, or Incorrect

The following background information is related

to this procedure:
Injector codes are 30 hexadecimal character codes
that are supplied with each injector and a card is also
included in the packaging for the injector. The code is
on a plate on the top of the injector. The code is used
by the ECM to balance the performance of the
injectors.
Refer to Troubleshooting, “Injector Code - Calibrate”
for further information.

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Illustration 46 g06360333
Typical code plate on an injector

Illustration 47 g06360350
Sequence for recording the injector code

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 288 M0095947-10
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Table 172
Troubleshooting Test Steps Values Results

1. Check for Active Diagnostic Codes Diagnostic codes Result: No diagnostic codes are present.

A. Connect the electronic service tool to the diagnostic Return the unit to service.
connector.
Result: One or more of the preceding diagnostic codes are
B. Turn the keyswitch to the ON position. active.

C. Check for active diagnostic codes or recently logged diag- Make a note of any cylinder numbers with the active diag-
nostic codes. nostic code. Proceed to Test Step 2.

2. Check the Injector Code on any Suspect Cylinders Diagnostic code Result: The card that was supplied with the injector is avail-
able for the suspect cylinders.
A. Connect the electronic service tool to the diagnostic con-
nector. Refer to Troubleshooting, “Electronic Service Tools”. Repair: Compare the injector code from the card with the
injector code that was recorded from the electronic service
B. Turn the keyswitch to the ON position. tool for each suspect cylinder.

C. Select the following menu options on the electronic service If the codes match, proceed to Test Step 3.
tool to obtain the injector codes from the ECM:
If the codes do not match, then use the electronic service
· “Service” tool to input the correct injector code. refer to Troubleshoot-
· “Calibrations” ing, Injector Code - Calibrate for the correct procedure.
· “Injector Codes Calibration”
Result: The card with the injector code is not available.
D. Make a note of the injector codes for any suspect cylinders.
Proceed to Test Step 3.

3. Manually Program the Injector Code Injector codes Result: The code on the injector is the same as the code in
the ECM.
A. Remove the valve mechanism cover. Refer to Disassembly
and Assembly, “Valve Mechanism Cover - Remove and Repair: The injector is incorrect for the engine. Replace the
Install”. injector with the correct injector for the engine. Refer to Dis-
assembly and Assembly, “Electronic Unit Injector - Re-
B. Make a note of the injector code that is on the injector in move” and refer to Disassembly and Assembly, “Electronic
any suspect cylinders. Unit Injector - Install”.

Note: Refer to Illustration 47 for the correct sequence for re- Result: The code on the injector is not the same as the
cording the injector code. code in the ECM.

C. Compare the injector code from the injector with the injector Repair: Use the electronic service tool to input the correct
code from the electronic service tool for each suspect cylinder. injector code. Refer to Troubleshooting, “Injector Code -
Calibrate” for the correct procedure.

Use the electronic service tool to clear all logged diagnostic

codes and then verify that the repair eliminates the fault.

If the procedure did not correct the issue, contact the Deal-
er Solutions Network (DSN).

i07980100

Injector Solenoid - Test

This procedure covers the following diagnostic

codes:

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Table 173
Diagnostic Trouble Codes for Injector Solenoid

J1939 Code Code Description Comments

Engine Injector Cylinder #01 : Cur- The Electronic Control Module (ECM) detects a low current condition for the injector
651-5
rent Below Normal solenoid.
Engine Injector Cylinder #02 : Cur-
652-5 The warning light will come on. The ECM will log the diagnostic code.
rent Below Normal
The engine will have low power and/or rough running.
Engine Injector Cylinder #03 : Cur- When an “Cylinder Cutout Test” is performed, a faulty electronic unit injector will indicate
653-5 a low reading in comparison with the other electronic unit injectors.
rent Below Normal
The ECM will continue to attempt to operate the electronic unit injector after the diagnos-
Engine Injector Cylinder #04 : Cur- tic code has been logged. An open circuit will prevent the operation of the electronic unit
654-5
rent Below Normal injector.

Engine Injector Cylinder #01 : Cur- The ECM detects a high current condition for the injector solenoid.
651-6
rent Above Normal
The warning light will come on. The ECM will log the diagnostic code.
Engine Injector Cylinder #02 : Cur-
652-6 The engine will have low power and/or rough running.
rent Above Normal
The ECM will continue to attempt to operate the electronic unit injector after the diagnos-
Engine Injector Cylinder #03 : Cur- tic code has been logged. A short circuit will prevent the operation of the electronic unit
653-6 injector.
rent Above Normal
Engine Injector Cylinder #04 : Cur-
654-6
rent Above Normal
Follow the troubleshooting procedure to identify the root cause of the fault.

Perform this procedure under conditions that are

identical to the conditions that exist when the fault
occurs. Typically, faults with the injector solenoid
occur when the engine is warmed up and/or when the
engine is under vibration (heavy loads).
These engines have Electronic Unit Injectors (EUI).
The ECM sends a pulse to each injector solenoid.
The pulse is sent at the correct time and at the
correct duration for a given engine load and speed.
The solenoid is mounted on top of the fuel injector
body.
An electrical fault can prevent the electronic unit
injector from operating. An open or short circuit in the
ECM that is unique to one electronic unit injector will
prevent that electronic unit injector from operating.
An open or short circuit in common wiring within the
ECM can prevent the two electronic unit injectors that
share that common wiring from operating.
If an open circuit is detected in the solenoid circuit, a
diagnostic code is generated. The ECM continues to
try to fire the injector. If a short circuit is detected, a
diagnostic code is generated. The ECM will
periodically try to fire the injector. If the short circuit
remains, this sequence of events will be repeated
until the fault is corrected.
“ Injector Solenoid Test””
Use the “Injector Solenoid Test” to diagnose an open
or short circuit diagnostic code while the engine is not
running. The “Injector Solenoid Test” will send a
signal to each solenoid. The electronic service tool
will indicate the status of the solenoid as “OK” ,
“Open” , or “Short” .

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Illustration 48 g06498109
Schematic of the circuit for the injector solenoids

Electrical Shock Hazard. The electronic unit injec-

tors use DC voltage. The ECM sends this voltage
to the electronic unit injectors. Do not come in
contact with the harness connector for the elec-
tronic unit injectors while the engine is operating.
Failure to follow this instruction could result in
personal injury or death.

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Table 174
Troubleshooting Test Steps Values Results

1. Download Information Using the Electronic Service Downloaded Result: The information was successfully saved.
Tool information
Proceed to Test Step 2.
A. Use the electronic service tool to download the “Product
Status Report” (PSR) with histograms before performing any Result: The electronic service tool information was not suc-
troubleshooting or clearing any diagnostic codes. cessfully saved.

Note: The downloaded information will be required by the Contact the Dealer Solutions Network (DSN) for guidance.
Dealer Solutions Network (DSN) if troubleshooting assistance
is required.

2. Create an Electronic Service Tool Snapshot Snapshot saved Result: The electronic service tool snapshot was success-
fully saved.
A. Select “Snapshot Viewer” on the electronic service tool, us-
ing menus: Information -> Snapshot -> Viewer Proceed to Test Step 3.

B. Select the event code and then click “View Graph” . Result: The electronic service tool snapshot was not suc-
cessfully saved.
C. Select the following parameter and then click OK.
Contact the DSN for guidance.
· Engine Speed

D. Select Save to "File to save" a Snapshot File (*.xml). This

file will contain all the data in the snapshot and not only the da-
ta shown on the graph.
Note: The downloaded information will be required by the
DSN if troubleshooting assistance is required.

3. Inspect Electrical Connectors and Wiring Loose connection Result: There is a fault in a connector or the wiring.
or damaged wire
A. Turn the keyswitch to the OFF position. A strong electrical Repair: Repair any faulty connectors or replace the wiring
shock hazard is present if the keyswitch is not turned OFF. harness. Ensure that all the seals are properly in place and
ensure that the connectors are correctly coupled.
B. Thoroughly inspect the connectors for the injectors and the Use the electronic service tool to clear all logged diagnostic
engine interface connector. Refer to Troubleshooting, “Electri- codes and verify that the repair eliminates the fault.
cal Connectors - Inspect” for details.
Result: All connectors, pins, and sockets are correctly
C. Check the harness and wiring for abrasion and for pinch coupled and/or inserted. The harness is free of corrosion,
points from the injectors to the ECM. abrasion, and pinch points.

Note: Do not disconnect the ECM connector at this stage. The Proceed to Test Step 4.
ECM can only be disconnected and reconnected 10 times be-
fore damage to the harness connector may occur.

(continued)

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(Table 174, contd)

Troubleshooting Test Steps Values Results

4. Use the “ Injector Solenoid Test”” “OK” , “OPEN” , or Result: All cylinders indicate “OK” - There is not an elec-
“SHORT” tronic fault with the injectors.
A. Start the engine.
Use the electronic service tool to clear all logged diagnostic
B. Allow the engine to warm up to the normal operating codes. Return the engine to service.
temperature.
Result: “OPEN”
C. Stop the engine.
Note the cylinders that indicate “OPEN” .
D. Turn the keyswitch to the ON position. Proceed to Test Step 5.

E. Access the “Injector Solenoid Test” by accessing the follow- Result: “SHORT”
ing display screens in order:
· “Diagnostics” Note the cylinders that indicate “SHORT” .
· “Diagnostic Tests” Proceed to Test Step 8.
· “Injector Solenoid Test”

F. Activate the test.

Note: Do not confuse the “Injector Solenoid Test” with the

“Cylinder Cutout Test” . The “Cylinder Cutout Test” is used to
shut off fuel to a specific cylinder while the engine is running.
The “Injector Solenoid Test” is used to actuate the injector sol-
enoids while the engine is not running.

5. Create a Short Circuit at the Suspect Injector Suspect injector Result: The electronic service tool displays “SHORT” for
indicates the cylinder with the jumper wire.
A. Turn the keyswitch to the OFF position. A strong electrical “SHORT”
shock hazard is present if the keyswitch is not turned OFF. Repair: Install a replacement fuel injector. Refer to Disas-
sembly and Assembly, “Electronic Unit Injector - Remove”
B. Disconnect the connector for the suspect injector. and Disassembly and Assembly, “Electronic Unit Injector -
Install”
C. Fabricate a jumper wire 100 mm (4 inch) long with termi-
nals on both ends of the wire. Result: The electronic service tool does not display
“SHORT” for the cylinder with the jumper wire.
D. Install the jumper wire between the two terminals on the
harness connector for the suspect injector. Remove all jumper wires. Proceed to Test Step 6.

E. Turn the keyswitch to the ON position.

F. Perform the “Injector Solenoid Test” at least two times.

G. Repeat this test for each suspect injector. Stop the “Injector
Solenoid Test” before handling the jumper wires.

(continued)

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(Table 174, contd)

Troubleshooting Test Steps Values Results

6. Create a Short Circuit at the Engine Interface Suspect injector Result: The electronic service tool displays “SHORT” for
Connector indicates the injector with the jumper wire. The fault is in the engine
“SHORT” wiring harness.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty wiring.
B. Disconnect the engine interface connector.
Result: The electronic service tool does not display
C. Fabricate a jumper wire 100 mm (4 inch) long with termi- “SHORT” for the injector with the jumper wire.
nals on both ends of the wire.
Remove all jumper wires. Proceed to Test Step 7.
D. Install the jumper wire between the injector supply and in-
jector return terminals on the engine interface connector.

E. Turn the keyswitch to the ON position.

F. Perform the “Injector Solenoid Test” at least two times.

G. Repeat this test for each suspect injector. Stop the “Injector
Solenoid Test” before handling the jumper wires.

7. Check the Wiring Between the Engine Interface Con- Less than 2 Ohms Result: At least one of the resistance measurements is
nector and the ECM for an Open Circuit greater than 2 Ohms. The fault is in the wiring between the
engine interface connector and the P2 ECM connector.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty wiring.
B. Disconnect the P2 connector from the ECM. Disconnect
the engine interface connector. Use the electronic service tool to perform the “Injector Sole-
noid Test” and verify that the repair eliminates the fault.
C. Inspect the P2/J2 connectors for damage or corrosion. Re-
fer to Troubleshooting, Electrical Connectors - Inspect for Result: The resistance measurements are less than 2
more information. Ohms.

D. Perform a 30 N (6.7 lb) pull test on each wire in the P2 con- Contact the Dealer Solutions Network (DSN).
nector that is associated with the active diagnostic code.

E. Use a suitable multimeter to measure the resistance be-

tween the suspect injector supply terminal on the engine inter-
face connector and the suspect injector supply terminal on the
P2 connector.

F. Use a suitable multimeter to measure the resistance be-

tween the suspect injector return terminal on the engine inter-
face connector and the suspect injector return terminal on the
P2 connector.

(continued)

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(Table 174, contd)

Troubleshooting Test Steps Values Results

8. Create an Open Circuit at the Suspect Injector Suspect injector Result: The electronic service tool displays “OPEN” for the
indicates “OPEN” suspect cylinder.
A. Turn the keyswitch to the OFF position. A strong electrical
shock hazard is present if the keyswitch is not turned OFF. Repair: Install a replacement fuel injector. Refer to Disas-
sembly and Assembly, “Electronic Unit Injector - Remove”
B. Disconnect the connector for the suspect injector. and Disassembly and Assembly, “Electronic Unit Injector -
Install”
C. Turn the keyswitch to the ON position. Use the electronic service tool to perform the “Injector Sole-
noid Test” and verify that the repair eliminates the fault.
D. Perform the “Injector Solenoid Test” at least two times.
Result: The electronic service tool does not display
E. Repeat this test for each suspect injector. Stop the “Injector “OPEN” for the suspect cylinder
Solenoid Test” before handling the jumper wires.
Proceed to Test Step 9.

9. Create an Open Circuit at the Engine Interface Suspect injector Result: The electronic service tool displays “OPEN” for the
Connector indicates “OPEN” suspect cylinder. The fault is in the engine wiring harness.

A. Turn the keyswitch to the OFF position. Repair: Repair the faulty wiring or replace the faulty wiring.
Use the electronic service tool to perform the “Injector Sole-
B. Disconnect the engine interface connector. noid Test” and verify that the repair eliminates the fault.

C. Turn the keyswitch to the ON position. Result: The electronic service tool does not display
“OPEN” for the suspect cylinder.
D. Perform the “Injector Solenoid Test” at least two times.
Proceed to Test Step 10.
E. Repeat this test for each suspect injector.

10. Check the Wiring Between the Engine Interface Con- Greater than 1 k Result: At least one of the resistance measurements is less
nector and the ECM for an Open Circuit Ohm than 1 k Ohm. There is a short in the wiring between the en-
gine interface connector and the ECM.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty wiring.
B. Disconnect the P2 connector from the ECM. Disconnect Use the electronic service tool to perform the “Injector Sole-
the engine interface connector. noid Test” and verify that the repair eliminates the fault.

C. Inspect the P2/J2 connectors for damage or corrosion. Re- Result: All resistance measurements are greater than 1 k
fer to Troubleshooting, Electrical Connectors - Inspect for Ohm.
more information.
Contact the Dealer Solutions Network (DSN).
D. Perform a 30 N (6.7 lb) pull test on each wire in the P2 con-
nector that is associated with the active diagnostic code.

E. Use a suitable multimeter to measure the resistance be-

tween the suspect injector supply terminal on the engine inter-
face connector and all other terminals on the engine interface
connector.

F. Use a suitable multimeter to measure the resistance be-

tween the suspect injector return terminal on the engine inter-
face connector and all other terminals on the engine interface
connector.

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i07708772

Mode Selection - Test

This procedure covers the following diagnostic code:

Table 175

Diagnostic Trouble Code for the Mode Selection Switch

J1939 Code Code Description Comments

The Electronic Control Module (ECM) detects a combination of switch positions for the
mode switches that has not been defined.
If equipped, the warning lamp will come on and the ECM will log the diagnostic code.
Engine Alternate Rating Select :
2882-2 The ECM will return the engine to the last good mode selection or setting.
Erratic, Intermittent, or Incorrect
The engine will start and the engine will default to the previous mode selection. The en-
gine may operate at reduced speed or reduced power depending on the mode that is
selected.
Follow the troubleshooting procedure to identify the root cause of the fault.

Use this procedure to check if the mode selection

switch operates correctly.
The mode selection switch inputs provide the
operator with the ability to select a maximum of four
different modes of operation. Different modes of
operation can be used giving the operator a means to
select the most efficient method of completing the
required work.
Each mode has a single fuel limit map, a rated
speed, and a matched fuel delivery. Each mode also
has a specific droop value for throttle 1 and throttle 2.
Table 176
Mode Switch 2 Switch 1 Enabled
Number
1 Open Open Y/N

2 Open Closed Y/N

3 Closed Open Y/N

4 Closed Closed Y/N

If a fault occurs in the circuit for either of the switches,

the mode of operation will be different to the mode
that was selected. If the mode of operation is not
enabled on the application, a 2882-2 diagnostic code
will become active.
During the following procedure, refer to the electrical
schematic for the application.
Complete the procedure in the order in which the
steps are listed.

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Table 177
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection Result: There is a fault in a connector or the wiring.
or damaged wire
A. Turn the keyswitch OFF. Repair: Repair any faulty connectors or replace the wiring
harness. Ensure that all the seals are properly in place and
B. Thoroughly inspect the P2 connector. Thoroughly inspect ensure that the connectors are correctly coupled.
the mode switch connectors, plugs, and interconnections on
the harness. Refer to Troubleshooting, “Electrical Connectors Use the electronic service tool to clear all logged diagnostic
- Inspect” for details. codes and verify that the repair eliminates the fault.

C. Perform a 30 N (6.7 lb) pull test on each of the wires in the Result: All connectors, pins, and sockets are correctly
P2 connector that are associated with the mode selector coupled and/or inserted. The harness is free of corrosion,
switches. abrasion, and pinch points.

D. Check the harness for abrasions and for pinch points from Proceed to Test Step 2.
the mode section switches to the ECM.

2. Check the Status of the Mode Selection Switch Switch status Result: The switch status changes on the electronic serv-
changes ice tool as the mode switches are cycled.
A. Turn the keyswitch to the OFF position.
Use the electronic service tool to clear all logged diagnostic
B. Connect the electronic service tool to the diagnostic codes. Return the engine to service.
connector.
Result: The switch status does not change as the mode
C. Turn the keyswitch to the ON position. switches are cycled.

D. Monitor the status screen on the electronic service tool. Proceed to Test Step 3.
Cycle the mode switch to the ON position and to the OFF
position.

3. Insert a Jumper at the Suspect Mode Switch Switch status Result: When the jumper wire is connected, the switch is in
“CLOSED” with the CLOSED position.
A. Turn the keyswitch to the OFF position. jumper installed
Repair: Replace the suspect mode selection switch.
B. Disconnect the connector for the suspect mode selection
switch. Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.
C. Fabricate a jumper wire and install the jumper wire across
the two contacts of the suspect switch. Result: When the jumper wire is connected, the switch is in
the OPEN position
D. Turn the keyswitch to the ON position. Monitor the status
screen on the electronic service tool. Connect the jumper wire Proceed to Test Step 4.
and then disconnect the jumper wire.

E. Turn the keyswitch to the OFF position. Remove the jumper

wire.

(continued)

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(Table 177, contd)

Troubleshooting Test Steps Values Results

4. Measure the Voltage at the Switch At least 10 VDC Result: One of the measured voltages is not within the ex-
pected range - The fault is in the wiring between the sus-
A. Turn the keyswitch to the OFF position. pect mode switch and the ECM.

B. Disconnect the connector for the mode selection switches. Repair: Repair the faulty wiring or replace the faulty wiring.

C. Turn the keyswitch to the ON position. Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.
D. Use the electronic service tool to turn both of the mode
switches to the ON position. Result: The measured voltages are within the expected
range.
E. Measure the voltage from the input of each mode switch to
a suitable ground. Proceed to Test Step 5.

5. Check the Wiring for an Open Circuit Less than 2 Ohms Result: One of the measured resistances is greater than 2
Ohms - The fault is in the wiring between the suspect mode
A. Turn the keyswitch to the OFF position. switch and the P2 connector.

B. Disconnect the connector for the mode switches. Repair: Repair the faulty wiring or replace the faulty wiring.

C. Disconnect the P2 connector from the ECM. Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.
D. Measure the resistance between the “Mode Switch 1” termi-
nal on the P2 connector and the applicable terminal on the Result: All measured resistances are less than 2 Ohms.
mode switch harness connector.
Proceed to Test Step 6.
E. Measure the resistance between the “Mode Switch 2” termi-
nal on the P2 connector and the applicable terminal on the
mode switch harness connector.

6. Check the Wiring for a Short Circuit Greater than 1k Result: One of the measured resistances is less than 100
Ohms Ohms. The fault is in the wiring between the ECM and the
A. Turn the keyswitch to the OFF position. mode switch.

B. Disconnect the connector for the mode switches. Repair: Repair the faulty wiring or replace the faulty wiring.

C. Disconnect the P2 connector from the ECM. Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.
D. Measure the resistance between the “Mode Switch 1” termi-
nal on the P2 connector and all other terminals on the P2 Result: All measured resistances are greater than 1k
connector. Ohms. There is a fault in the ECM.

E. Measure the resistance between the “Mode Switch 2” termi- Contact the Dealer Solutions Network (DSN).
nal on the P2 connector and all other terminals on the P2
connector.

i08125425

Motorized Valve - Test

This procedure covers the following
codes:

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Table 178
Diagnostic Trouble Codes for the Motorized Valves

J1939
Code Description Notes
1188–7 Engine Turbocharger #1 Wastegate The Electronic Control Module (ECM) detects the signal from the turbocharger Electronic
Drive : Not Responding Properly Wastegate (EWG) position sensor indicates that the valve is not in the desired position.

This diagnostic code can be caused by a loss of the 5 VDC supply to the EWG position sensor
or a mechanical fault with the valve.
2791-5 Engine Exhaust Gas Recirculation The ECM detects a low current condition in the output for the NOx Reduction System (NRS)
(EGR) Valve Control : Current Be- valve.
low Normal
2791-6 Engine Exhaust Gas Recirculation The ECM detects a high current condition in the output for the NRS valve.
(EGR) Valve Control : Current
Above Normal
2791-7 Engine Exhaust Gas Recirculation The ECM detects the signal from the NRS valve position sensor indicates that the valve is not
(EGR) Valve Control : Not Respond- in the desired position.
ing Properly
This diagnostic code can be caused by a loss of the 5 VDC supply to the EGR valve position
sensor or a mechanical fault with the valve.
3464-5 Engine Throttle Actuator 1 Control The ECM detects A low current condition in the output for the engine intake throttle valve.
Command : Current Below Normal
3464-6 Engine Throttle Actuator 1 Control The ECM detects a high current condition in the output for the engine intake throttle valve.
Command : Current Above Normal
3464-7 Engine Throttle Actuator 1 Control The ECM detects the signal from the intake throttle valve position sensor indicates that the
Command : Not Responding valve is not in the desired position.
Properly This diagnostic code can be caused by a loss of the 5 VDC supply to the intake throttle valve
position sensor or a mechanical fault with the valve.

5421–5 Engine Turbocharger Wastegate The ECM detects A low current condition in the output for the turbocharger EWG.
Actuator #1 : Current Below Normal
5421–6 Engine Turbocharger Wastegate The ECM detects a high current condition in the output for the turbocharger EWG.
Actuator #1 : Current Above Normal

The following background information is related The “Air System Motor Valve Verification Test” will
to this procedure: identify whether the NRS valve, the intake throttle
valve, and the turbocharger EWG are working
NRS Valve correctly. This test must be performed when the
engine speed is zero and the battery voltage is within
The NRS valve is used to control the amount of an acceptable range. For a 12V system, the test must
exhaust gas which is recirculated into the intake
manifold. only be performed when the battery voltage is
between 9V and 16V. For a 24V system, the test
The amount of exhaust gas that is required is must only be performed when the battery voltage is
calculated by the software that is contained in the between 18V and 32V. If the battery voltage is out of
ECM. The NRS valve is controlled by a PWM signal the required range, the test will be aborted.
from the ECM.
The “Air System Motor Valve Verification Test” will
Intake Throttle Valve actively check position sensor diagnostics, motor
short diagnostics, and motor open circuit diagnostics.
The intake throttle valve is used to increase the The test will abort if any of these diagnostic codes
exhaust gas temperature to aid the regeneration become active.
process.
Turbocharger EWG
The EWG is a valve that allows exhaust gas to
bypass the turbine wheel of the turbocharger. The
position of the valve varies the amount of exhaust
gas that flows into the turbine.
“ Air System Motor Valve Verification Test””

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If the engine speed is not zero while the test is being

performed, the test will be aborted. If no electrical
diagnostic codes are active, the test will calibrate the
NRS valve minimum position, the intake throttle valve
minimum and maximum position, and the
turbocharger EWG maximum position. The test then
moves the valves to various positions and checks the
position sensor within each valve to confirm that the
valve has responded correctly. Each valve will be
tested in turn, starting with the NRS valve. If a test
threshold is exceeded or any related diagnostic
codes become active, the test will abort and generate
a service tool error identifier.

Illustration 49 g06356434
Schematic diagram for the motorized valves

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Table 179
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found.
or connector
A. Thoroughly inspect connectors for the motorized valves. Repair: Repair the damaged wire or the damaged connector.
Refer to Troubleshooting, “Electrical Connectors - Inspect” for Use the electronic service tool to clear all logged diagnostic co-
details. des. Perform the “Air System Motor Valves Verification Test”
and verify that the repair eliminates the fault.
B. Thoroughly inspect the engine interface connector. Refer
to Troubleshooting, “Electrical Connectors - Inspect” for Result: All connectors, pins, and sockets are correctly con-
details. nected and/or inserted and the harness is free of corrosion, of
abrasion or of pinch points.

Proceed to Test Step 2.

2. Check for Diagnostic Codes Diagnostic Result: A -7 diagnostic code is active or recently logged for
codes one or more of the motorized valves
A. Turn the keyswitch to the OFF position.
Proceed to Test Step 3.
B. Connect the electronic service tool to the diagnostic
connector. Result: A -5 diagnostic code is active or recently logged for
one or more of the motorized valves.
C. Turn the keyswitch to the ON position.
Proceed to Test Step 5.
D. Monitor the electronic service tool for active diagnostic co-
des and/or logged diagnostic codes. Result: A -6 diagnostic code is active or recently logged for
one or more of the motorized valves.

Proceed to Test Step 8.

3. Measure the Sensor Supply Voltage at the Valve 4.84 V to 5.16 V Result: The measured voltage is within the expected range.
Connector
Repair: Use the electronic service tool to perform the “Air Sys-
A. Turn the keyswitch to the OFF position. tem Motor Valves Verification Test” . If the test passes, there
may be an intermittent fault. Refer to Troubleshooting, Electri-
B. Disconnect the suspect valve from the engine harness. cal Connectors - Inspect to identify intermittent faults.
If the test fails, install a replacement for the suspect valve. Re-
C. Turn the keyswitch to the ON position. fer to Disassembly and Assembly for more information.
If the turbocharger EWG is replaced, use the electronic service
D. Measure the voltage at the harness connector for the valve tool to perform the “Turbocharger Wastegate Actuator Re-
from the 5 V supply terminal of the position sensor to the sen- placement Reset” .
sor ground terminal. If the NRS valve is replaced, use the electronic service tool to
perform the “EGR Valve Replacement Reset” .
If the intake throttle valve is replaced, use the electronic serv-
ice tool to perform the “Engine Throttle Valve Replacement Re-
set” .
Use the electronic service tool to clear all logged diagnostic co-
des. Perform the “Air System Motor Valves Verification Test”
and verify that the repair eliminates the fault.

Result: The measured voltage is not within the expected

range.

Reconnect the valve connector. Proceed to Test Step 4.

(continued)

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 M0095947-10 301
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(Table 179, contd)

Troubleshooting Test Steps Values Results

4. Measure the Sensor Supply Voltage at the Engine Inter- 4.84 V to 5.16 V Result: The measured voltage is within the expected range.
face Connector The fault is in the 5 VDC supply wire or the ground wire be-
tween the suspect valve and the engine interface connector.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty wiring.
B. Disconnect the engine interface connector. Use the electronic service tool to clear all logged diagnostic co-
des. Perform the “Air System Motor Valves Verification Test”
C. Turn the keyswitch to the ON position. and verify that the repair eliminates the fault.

D. Measure the voltage at the engine interface connector on Result: The measured voltage is not within the expected
the harness between the engine and the ECM from the 5 range.
VDC sensor supply terminal for the suspect valve to the sen- The fault is in the 5 VDC supply wire or the ground wire be-
sor ground terminal . tween the ECM and the engine interface connector.

Repair: Repair the faulty wiring or replace the faulty wiring.

Use the electronic service tool to clear all logged diagnostic co-
des. Perform the “Air System Motor Valves Verification Test”
and verify that the repair eliminates the fault.

5. Create a Short Circuit at the Valve Connector Diagnostic Result: A -6 is active with the jumper installed.
codes
A. Turn the keyswitch to the OFF position. Repair: Reconnect the valve. Start the engine.
Check for active diagnostic codes on the electronic service
B. Disconnect the connector for the suspect valve. tool. Wait at least 30 seconds in order for the codes to be
displayed.
C. Fabricate a jumper wire that is 150 mm (6 inch) long. If the -5 diagnostic code returns, then replace the valve. Refer
to Disassembly and Assembly for the correct procedure.
D. Install the jumper between the PWM signal and return pins If the turbocharger EWG is replaced, use the electronic service
on the connector for the suspect valve to create a short tool to perform the “Turbocharger Wastegate Actuator Re-
circuit. placement Reset” .
If the NRS valve is replaced, use the electronic service tool to
E. Turn the keyswitch to the ON position. Check for active di- perform the “EGR Valve Replacement Reset” .
agnostic codes on the electronic service tool. If the intake throttle valve is replaced, use the electronic serv-
ice tool to perform the “Engine Throttle Valve Replacement Re-
F. Turn the keyswitch to the OFF position. set” .
Use the electronic service tool to clear all logged diagnostic co-
G. Remove the jumper wire. des. Perform the “Air System Motor Valves Verification Test”
and verify that the repair eliminates the fault.

Result: A -5 diagnostic code is still active with the jumper

installed.

Proceed to Test Step 6.

(continued)

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 302 M0095947-10
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(Table 179, contd)

Troubleshooting Test Steps Values Results

6. Create a Short Circuit at the Engine Interface Diagnostic Result: A -6 diagnostic code is active when the jumper is
Connector codes installed.
The fault is in the PWM supply wire or the return wire between
A. Turn the keyswitch to the OFF position. the suspect valve and the engine interface connector.

B. Disconnect the engine interface connector. Repair: Repair the faulty wiring or replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic co-
C. Fabricate a jumper wire that is 150 mm (6 inch) long. In- des. Perform the “Air System Motor Valves Verification Test”
stall the jumper wire between the PWM supply and return ter- and verify that the repair eliminates the fault.
minals for the suspect valve on the engine interface
connector on the harness between the engine and the ECM. Result: A -5 diagnostic code is still active with the jumper
installed.
D. Turn the keyswitch to the ON position. Wait at least 30 sec-
onds for activation of the diagnostic codes. Proceed to Test Step 7.
Note: Diagnostic codes for all the engine sensors will be ac-
tive with the engine interface connector disconnected. Ignore
all other diagnostic codes and only look for codes that relate
to the suspect valve.

E. Look for an active -6 diagnostic code for the suspect valve.

F. Remove the jumper wire.

7. Check the Wiring Between the Engine Interface Con- Less than 2 Result: At least one of the resistance measurements is great-
nector and the ECM for an Open Circuit Ohms er than 2 Ohms. The fault is in the wiring between the engine
interface connector and the P2 ECM connector.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty wiring.
B. Disconnect the P2 connector from the ECM. Disconnect
the engine interface connector. Use the electronic service tool to clear all logged diagnostic co-
des. Perform the “Air System Motor Valves Verification Test”
C. Inspect the P2/J2 connectors for damage or corrosion. Re- and verify that the repair eliminates the fault.
fer to Troubleshooting, Electrical Connectors - Inspect for
more information. Result: The resistance measurements are less than 2 Ohms.

D. Perform a 30 N (6.7 lb) pull test on each wire in the P2 Contact the Dealer Solutions Network (DSN).
connector that is associated with the active diagnostic code.

E. Use a suitable multimeter to measure the resistance be-

tween the suspect valve PWM signal terminal on the engine
interface connector and the suspect valve PWM supply termi-
nal on the P2 connector.

F. Use a suitable multimeter to measure the resistance be-

tween the suspect valve PWM return terminal on the engine
interface connector and the suspect valve PWM return termi-
nal on the P2 connector.

(continued)

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 M0095947-10 303
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(Table 179, contd)

Troubleshooting Test Steps Values Results

8. Create an Open Circuit at the Valve Connector Diagnostic Result: A -5 diagnostic code is active with the valve
Codes disconnected.
A. Turn the keyswitch to the OFF position.
Repair: Reconnect the valve. Start the engine.
B. Disconnect the connector for the suspect valve to create Check for active diagnostic codes on the electronic service
an open circuit. tool. Wait at least 30 seconds in order for the codes to be
displayed.
C. Turn the keyswitch to the ON position. Check for active di- If the -6 diagnostic code returns, then replace the valve. Refer
agnostic codes on the electronic service tool. Wait at least 30 to Disassembly and Assembly for the correct procedure.
seconds in order for the codes to be displayed. If the turbocharger EWG is replaced, use the electronic service
tool to perform the “Turbocharger Wastegate Actuator Re-
placement Reset” .
If the NRS valve is replaced, use the electronic service tool to
perform the “EGR Valve Replacement Reset” .
If the intake throttle valve is replaced, use the electronic serv-
ice tool to perform the “Engine Throttle Valve Replacement Re-
set” .
Use the electronic service tool to clear all logged diagnostic co-
des. Perform the “Air System Motor Valves Verification Test”
and verify that the repair eliminates the fault.

Result: A -6 diagnostic code is still active with the valve

disconnected.

Proceed to Test Step 9.

9. Create an Open Circuit at the Engine Interface Diagnostic Result: A -5 diagnostic code is active with the engine interface
Connector codes connector disconnected.
The fault is in the wiring between the suspect valve and the en-
A. Turn the keyswitch to the OFF position. gine interface connector.

B. Disconnect the engine interface connector. Repair: Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic co-
C. Turn the keyswitch to the ON position. Wait at least 30 sec- des. Perform the “Air System Motor Valves Verification Test”
onds for activation of the diagnostic codes. and verify that the repair eliminates the fault.
Note: Diagnostic codes for all the engine sensors will be ac-
tive with the engine interface connector disconnected. Ignore Result: A -6 diagnostic code is still active with the engine inter-
all other codes and only look for codes that relate to the sus- face connector disconnected.
pect valve.
Proceed to Test Step 10.
D. Check for an active -5 diagnostic code for the suspect
valve.

E. Turn the keyswitch to the OFF position.

10. Check the Wiring Between the Engine Interface Con- Diagnostic Result: At least one of the resistance measurements is less
nector and the ECM for an Open Circuit codes than 1 k Ohm. There is a short in the wiring between the en-
gine interface connector and the ECM.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty wiring.
B. Disconnect the P2 connector from the ECM. Disconnect Use the electronic service tool to clear all logged diagnostic co-
the engine interface connector. des. Perform the “Air System Motor Valves Verification Test”
and verify that the repair eliminates the fault.
C. Inspect the P2/J2 connectors for damage or corrosion. Re-
fer to Troubleshooting, Electrical Connectors - Inspect for Result: All resistance measurements are greater than 1 k
more information. Ohm.

(continued)

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 304 M0095947-10
Circuit Tests

(Table 179, contd)

Troubleshooting Test Steps Values Results
D. Perform a 30 N (6.7 lb) pull test on each wire in the P2 Contact the Dealer Solutions Network (DSN).
connector that is associated with the active diagnostic code.

E. Use a suitable multimeter to measure the resistance be-

tween the suspect injector supply terminal on the engine in-
terface connector and all other terminals on the engine
interface connector.

F. Use a suitable multimeter to measure the resistance be-

tween the suspect injector return terminal on the engine inter-
face connector and all other terminals on the engine interface
connector.

i07622766

NOx Sensor Supply - Test

Use this procedure if any of the diagnostic codes in

Table180 are active or easily repeated.
Table 180
Diagnostic Trouble Codes for the NOx Sensor Supply

J1939 Code Code Description Comments

5758-11 Engine Exhaust NOx Level Sensor Power Supply: The ECM detects voltage that is outside the acceptable value.
Other Failure Mode
5759-11 Aftertreatment #1 Outlet#1 NOx Level Sensor The ECM detects voltage that is outside the acceptable value.
Power Supply: Other Failure Mode

Illustration 50 g06381739
Schematic for the NOx sensor power supply circuit

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 M0095947-10 305
Circuit Tests

Table 181
Troubleshooting Procedure for the NOx Sensor Power Supplies

Troubleshooting Test Steps Value Results

1. Check the Voltage at the Sensor Connector Battery voltage Result: The measured voltage is equal to battery voltage.

A. Turn the keyswitch to the OFF position. Repair: Install a replacement NOx sensor.

B. Disconnect the connector for the suspect NOx sensor. Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.
C. Turn the keyswitch to the ON position.
Result: The measured voltage is not equal to battery voltage.
D. Use the electronic service tool to switch on the override
for the suspect NOx sensor. Proceed to Test Step 2.

E. Measure the voltage between terminal 1 and terminal 4 on

the harness connector for the sensor.

F. Turn the keyswitch to the OFF position.

2. Check the Wiring for an Open Circuit Less than 2 Result: Both resistance measurements are less than 2
Ohms Ohms.
A. Disconnect the SCR main relay.
Proceed to Test Step 3.
B.Use a suitable multimeter to measure the resistance be-
tween terminal 1 on the harness connector for the suspect Result: At least one of the resistance measurements is great-
sensor and the SCR main relay. er than 2 Ohms. There is an open circuit in the wiring to the
suspect NOx sensor.
C. Use a suitable multimeter to measure the resistance be-
tween terminal 4 on the harness connector for the suspect Repair:
sensor and a suitable ground.
Repair the faulty wiring or replace the faulty wiring.

Use the electronic service tool to clear all logged diagnostic

codes and verify that the repair eliminates the fault.

3. Check the Wiring for a Short Circuit Greater than 1k Result: The resistance measurement is greater than 1k
Ohm Ohm.
A. Turn the keyswitch to the OFF position.
Note: If there are more active diagnostic codes for the SCR
B. Disconnect the connector for the suspect NOx sensor. system, there may be a fault with the SCR relay. Refer to
Troubleshooting, Relay - Test (SCR Main Relay).
C. Measure the resistance between terminal 1 on the har-
ness connector for the suspect sensor and a suitable ground. Contact the Dealer Solutions Network (DSN).

Result: The resistance measurement is less than 1 k Ohm.

There is a short in the power supply wiring to the suspect
NOx sensor.

Repair: Repair the faulty wiring or replace the faulty wiring.

Use the electronic service tool to clear all logged diagnostic

codes and verify that the repair eliminates the fault.

If the procedure did not correct the issue, contact the Dealer
Solutions Network (DSN).

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i07897336

Relay - Test
(Start Relay)

This procedure covers the following diagnostic

codes:
Table 182
Diagnostic Trouble Codes for the Start Relay

J1939 Code Code Description Comments

The Electronic Control Module (ECM) detects a low current condition
677-5 Engine Starter Motor Relay Current Below Normal
(open circuit) in the start relay control circuit.

The Electronic Control Module (ECM) detects a high current condition

677-6 Engine Starter Motor Relay Current Above Normal
(short circuit) in the start relay control circuit.

Follow the troubleshooting procedure to identify the root cause of the fault.

During the following procedure, refer to the electrical

schematic for the application.
Complete the procedure in the order in which the
steps are listed.
Table 183
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection Result: There is a fault in a connector or the wiring.
or damaged wire
A. Check that the fuses are not blown. Repair: Repair any faulty connectors or replace the wiring
harness. Ensure that all the seals are properly in place and
B. Inspect the terminals on the start relay. Refer to Trouble- ensure that the connectors are correctly coupled.
shooting, “Electrical Connector - Inspect” for details.
Replace any blown fuses.
C. Perform a 30 N (6.7 lb) pull test on each of the wires in the
ECM connector that are associated with the start relay. Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.
D. Check the harness for abrasion and pinch points from the
start relay back to the ECM. Result: All connectors, pins, and sockets are correctly
coupled and/or inserted. The harness is free of corrosion,
abrasion, and pinch points. The fuses are not blown.

Proceed to Test Step 2.

2. Check for Active Diagnostic Codes Diagnostic codes Result: Diagnostic code 677-5 is active or recently logged.

A. Connect the electronic service tool to the diagnostic Proceed to Test Step 3.
connector.
Result: Diagnostic code 677-6 is active or recently logged.
B. Turn the keyswitch to the ON position.
Note: Do not start the engine. Proceed to Test Step 6.

C. Use the electronic service tool to check for active diagnos-

tic codes.

(continued)

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 M0095947-10 307
Circuit Tests

(Table 183, contd)

Troubleshooting Test Steps Values Results

3. Check the Battery Supply Voltage at the Relay At least 11 VDC Result: The voltage is not within the expected range.
Connector for a 12 VDC
system. Repair: Repair or replace the battery supply wiring to the
A. Turn the keyswitch to the OFF position. start relay.

B. Turn the keyswitch to the ON position. Do not start the Use the electronic service tool to clear all logged diagnostic
engine. codes and verify that the repair eliminates the fault.

C. Measure the voltage between the battery input terminal on Result: The voltage is within the expected range.
the relay and a suitable ground.
Proceed to Test Step 4.

4. Create a Short Circuit at the Relay Connector Diagnostic code Result: A 677-6 diagnostic code is active with the jumper
installed.
A. Turn the keyswitch to the OFF position.
Repair: Install a replacement start relay.
B. Remove the start relay.
Use the electronic service tool to clear all logged diagnostic
C. Fabricate a jumper wire. Install the jumper wire between codes and verify that the repair eliminates the fault.
terminal 1 and terminal 2 on the harness connector for the
start relay. Result: The 677-5 diagnostic code is still active.

D. Turn the keyswitch to the ON position. Proceed to Test Step 5.

E. Use the electronic service tool to check for active diagnos-

tic codes. Wait at least 30 seconds for activation of the diag-
nostic codes.

F. Turn the keyswitch to the OFF position and remove the

jumper wire.

5. Check the Relay Control Wiring for an Open Circuit Less than 5 Ohms Result: At least one of the resistance measurements is
greater than 5 Ohms - the fault is in the wiring for the start
A. Verify that the keyswitch is in the OFF position. relay control circuit.

B. Disconnect the P1 connector from the ECM. Repair: Repair the faulty wiring or replace the faulty wiring.

C. Inspect the P1 connector. Refer to Troubleshooting, “Elec- Result: Both resistance measurements are less than 5
trical Connector - Inspect” for details. Ohms.

D. Measure the resistance between Terminal 1 on the harness Contact the Dealer Solutions Network (DSN).
connector for the start relay and the “Start Relay Control” ter-
minal on the P1 connector.

E. Measure the resistance between Terminal 2 on the harness

connector for the start relay and ground.
Note: If terminal 2 is connected to the engine ECM, measure
the resistance between terminal 2 on the harness connector
and the appropriate terminal on the P1 connector. Refer to the
Electrical Schematic for the application.

(continued)

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 308 M0095947-10
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(Table 183, contd)

Troubleshooting Test Steps Values Results

6. Create an Open Circuit at the Relay Diagnostic codes Result: A 677-5 diagnostic code is active with the relay
disconnected.
A. Turn the keyswitch to the OFF position.
Repair: Install a replacement start relay.
B. Disconnect the start relay.
Use the electronic service tool to clear all logged diagnostic
C. Use the electronic service tool to check for active diagnos- codes and verify that the repair eliminates the fault.
tic codes. Wait at least 30 seconds for activation of the diag-
nostic codes. Result: The 677-6 diagnostic code is still active with the re-
lay disconnected.

Proceed to Test Step 7.

7. Check the Wiring Between the Relay and the ECM for a Greater than 1.0 k Result: At least one of the resistance measurements is less
Short Circuit Ohm than 1.0 k Ohm. There is a short in the wiring between the
relay and the ECM.
A. Disconnect the P1 connector.
Repair: Repair the faulty wiring or replace the faulty wiring.
B. Inspect the P1 connector. Refer to Troubleshooting, “Elec-
trical Connectors - Inspect” for details. Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.
C. Measure the resistance between the “Start Relay Control”
terminal and all other terminals on the P1 connector. Result: All resistance measurements are greater than 1.0 k
Ohm.

Contact the Dealer Solutions Network (DSN).

i08166818

Relay - Test
(SCR Main Relay)

This procedure covers the following diagnostic

codes:
Table 184
Diagnostic Trouble Codes for the SCR Main Relay

J1939 Code Code Description Comments

Aftertreatment #1 DEF Control Module Relay Con- The Electronic Control Module (ECM) detects a low current condition in
5965-5
trol : Current Below Normal the Selective Catalytic Reduction (SCR) main relay control circuit.

Aftertreatment #1 DEF Control Module Relay Con- The ECM detects a high current condition in the SCR main relay control
5965-6
trol : Current Above Normal circuit.
Follow the troubleshooting procedure to identify the root cause of the fault.

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 M0095947-10 309
Circuit Tests

Illustration 51 g06576319
Schematic diagram for the SCR main relay

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the line heater connectors
and the ECM connectors.
Table 185
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection Result: There is a fault in a connector or the wiring.
or damaged wire
A. Check that the fuses are not blown. Repair: Repair any faulty connectors or replace the wiring
harness. Ensure that all the seals are properly in place and
B. Inspect the terminals on the SCR main relay. Refer to Trou- ensure that the connectors are correctly coupled.
bleshooting, “Electrical Connector - Inspect” for details.
Replace any blown fuses.
C.Thoroughly inspect any connectors between the SCR main
relay and the ECM Use the electronic service tool to clear all logged diagnostic
codes.
D. Check the harness for abrasion and pinch points from the Use the electronic service tool to perform the “Aftertreat-
SCR main relay back to the ECM. ment System Functional Test” to verify that the repair elimi-
nates the fault.
Note: Do not disconnect the ECM connector at this stage.
The ECM can only be disconnected and reconnected 10 Result: All connectors, pins, and sockets are correctly
times before damage to the harness connector may occur. coupled and/or inserted. The harness is free of corrosion,
abrasion, and pinch points. The fuses are not blown.

Proceed to Test Step 2.

2. Check for Active Diagnostic Codes Diagnostic codes Result: Diagnostic code 5965-5 is active or recently logged.

A. Connect the electronic service tool to the diagnostic Proceed to Test Step 3.
connector.
Result: Diagnostic code 5965-6 is active or recently logged.
B. Turn the keyswitch to the ON position.
Note: Do not start the engine. Proceed to Test Step 6.

C. Use the electronic service tool to check for active diagnos-

tic codes.

(continued)

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 310 M0095947-10
Circuit Tests

(Table 185, contd)

Troubleshooting Test Steps Values Results

3. Create a Short Circuit at the Relay Connector Diagnostic code Result: A 5965-6 diagnostic code is active with the jumper
installed.
A. Turn the keyswitch to the OFF position.
Repair: Install a replacement SCR main relay.
B. Remove the SCR main relay.
Use the electronic service tool to perform the “Aftertreat-
C. Fabricate a jumper wire. Install the jumper wire between ment System Functional Test” to verify that the repair elimi-
terminal 85 and terminal 86 on the harness connector for the nates the fault.
SCR main relay.
Result: The 5965-5 diagnostic code is still active.
D. Turn the keyswitch to the ON position.
Proceed to Test Step 4.
E. Use the electronic service tool to check for active diagnos-
tic codes. Wait at least 30 seconds for activation of the diag-
nostic codes.

F. Turn the keyswitch to the OFF position and remove the

jumper wire.

4. Check the Wiring Between the SCR Main Relay and the Less than 2 Ohms Result: The resistance is greater than 2 Ohms. There is a
Interface Connector (if equipped) for an Open Circuit fault in the wiring between the SCR main relay connector
and the interface connector.
Note: This step is only applicable if an interface connector is
installed between the SCR main relay and the ECM. Refer to Repair: Repair the faulty wiring or replace the faulty wiring.
the Electrical Schematic for the application for more informa-
tion. Proceed to Test Step 5 if no interface connector is Use the electronic service tool to perform the “Aftertreat-
installed. ment System Functional Test” to verify that the repair elimi-
nates the fault.
A. Turn the keyswitch to the OFF position.
Result: All measured resistances are less than 2 Ohms.
B. Disconnect the connector for the SCR main relay. Discon-
nect the interface connector between the SCR main relay and Reconnect all connectors. Proceed to Test Step 5.
the ECM.

C. Use a suitable multimeter to measure the resistance be-

tween terminal 85 on the harness connector for the suspect
line heater and the appropriate pin/terminal on the interface
connector.

5. Check the Relay Control Wiring for an Open Circuit Less than 2 Ohms Result: At least one of the resistance measurements is
greater than 2 Ohms. The fault is in the wiring between the
A. Verify that the keyswitch is in the OFF position. SCR main relay and the ECM.

B. Disconnect the P1 connector from the ECM. Repair: Repair the faulty wiring or replace the faulty wiring.

C. Inspect the P1 connector. Refer to Troubleshooting, “Elec- Result: Both resistance measurements are less than 2
trical Connector - Inspect” for details. Ohms.

D. Measure the resistance between Terminal 85 on the har- Contact the Dealer Solutions Network (DSN).
ness connector for the SCR main relay and P1:50.

(continued)

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 M0095947-10 311
Circuit Tests

(Table 185, contd)

Troubleshooting Test Steps Values Results

6. Create an Open Circuit at the Relay Diagnostic codes Result: A 5965-5 diagnostic code is active with the relay
disconnected.
A. Turn the keyswitch to the OFF position.
Repair: Install a replacement SCR main relay.
B. Disconnect the SCR main relay.
Use the electronic service tool to perform the “Aftertreat-
C. Use the electronic service tool to check for active diagnos- ment System Functional Test” to verify that the repair elimi-
tic codes. Wait at least 30 seconds for activation of the diag- nates the fault.
nostic codes.
Result: The 5965-6 diagnostic code is still active with the
relay disconnected.

Proceed to Test Step 7.

Result: At least one of the resistance measurements is less

7. Check the Wiring Between the SCR Main Relay and the Greater than 1 k than 1 k Ohm. There is a fault in the wiring between the
Interface Connector (if equipped) for a Short Circuit Ohm SCR main relay connector and the interface connector.

Note: This step is only applicable if an interface connector is Repair: Repair the faulty wiring or replace the faulty wiring.
installed between the SCR main relay and the ECM. Refer to
the Electrical Schematic for the application for more informa- Use the electronic service tool to perform the “Aftertreat-
tion. Proceed to Test Step 8 if no interface connector is ment System Functional Test” to verify that the repair elimi-
installed. nates the fault.

A. Turn the keyswitch to the OFF position. Result: All measured resistances are greater than 1 k Ohm.

B. Disconnect the connector for the SCR main relay. Discon- Reconnect all connectors. Proceed to Test Step 8.
nect the interface connector between the SCR main relay and
the ECM.

C. Use a suitable multimeter to measure the resistance be-

tween the DEF line heater return terminal on the interface
connector and all other terminals on the interface connector.

8. Check the Wiring Between the Relay and the ECM for a Greater than 1 k Result: At least one of the resistance measurements is less
Short Circuit Ohm than 1 k Ohm. There is a short in the wiring between the re-
lay and the ECM.
A. Disconnect the P1 connector.
Repair: Repair the faulty wiring or replace the faulty wiring.
B. Inspect the P1 connector. Refer to Troubleshooting, “Elec-
trical Connectors - Inspect” for details. Use the electronic service tool to perform the “Aftertreat-
ment System Functional Test” to verify that the repair elimi-
C. Measure the resistance between P1:50 and all other termi- nates the fault.
nals on the P1 connector.
Result: All resistance measurements are greater than 1 k
Ohm.

Contact the Dealer Solutions Network (DSN).

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i07818073

Sensor Calibration Required -

Test

The Electronic Control Module (ECM) performs

calibrations of pressure sensors automatically. Use
this procedure if the diagnostic code in Table 186 is
active or easily repeated.
Table 186
Diagnostic Codes Table for Sensor Calibration

J1939 Code Code Description Comments

411-13 Engine Exhaust Gas Recirculation The ECM detects the following conditions:
Differential Pressure : Out of The NRS differential pressure is outside the acceptable range during initi-
Calibration alization check, or during sensor calibration when the engine is not
running.
The warning lamp will come on and the engine will be derated.
The code is logged.

3251–13 Aftertreatment #1 DPF Differential The ECM detects the following conditions:
Pressure : Out of Calibration The Diesel Particulate Filter (DPF) differential pressure is outside the ac-
ceptable range during initialization check, or during sensor calibration
when the engine is not running.
The warning lamp will come on and the engine will derate. The code is
logged.

3358-13 Engine Exhaust Gas Recirculation In- The ECM detects the following conditions:
let Pressure : Out of Calibration The offset between the NRS inlet pressure and the barometric pressure is
outside the acceptable range during initialization check.
The offset between the NRS inlet pressure and the barometric pressure is
outside the acceptable range during sensor calibration when the engine is
not running.
The warning lamp will come on and the engine will derate. The code is
logged.

3563-13 Engine Intake Manifold #1 Absolute The ECM detects the following conditions:
Pressure : Out of Calibration The offset between the intake manifold air pressure and the barometric
pressure is outside the acceptable range during initialization check.
The offset between the intake manifold air pressure and the barometric
pressure is outside the acceptable range during sensor calibration with
the engine not running.
The warning lamp will come on and the engine will derate.
The code is logged.

3609–13 DPF #1 Intake Pressure : Out of The ECM detects the following conditions:
Calibration The offset between the DPF inlet pressure and the barometric pressure is
outside the acceptable range during initialization check.
The offset between the DPF inlet pressure and the barometric pressure is
outside the acceptable range during sensor calibration with the engine not
running.
The warning lamp will come on and the engine will derate.
The code is logged.

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Table 187
Troubleshooting Test Steps Values Results

1. Check For Active Diagnostic Codes Diagnostic codes Result: There are no active diagnostic codes for the
pressure sensors.
A. Turn the keyswitch to the OFF position.
Repair: If there are logged diagnostic codes for the in-
B. Connect the electronic service tool to the diagnostic take manifold pressure sensor, the fault may be
connector. intermittent.
Refer to Troubleshooting, “Electrical Connectors - In-
C. Turn the keyswitch to the ON position. spect” to identify intermittent faults.

D. Use the electronic service tool to check that coolant tem- Result: One or more of the temperature sensors is read-
perature, intake manifold air temperature, and NRS tempera- ing less than 5° C (41° F).
ture are all at least 5° C (41° F).
Proceed to Test Step 2.
Note: Wait at least 10 seconds in order for the diagnostic co-
des to become active. Result: There is an active -3 or -4 diagnostic code for a
pressure sensor or the barometric pressure sensor.
E. Use the electronic service tool to monitor active diagnostic
codes or recently logged diagnostic codes. Look for an active Repair: Troubleshoot these codes before continuing
or logged -3 or -4 codes for the pressure sensor or the baro- with this procedure.
metric pressure sensor.
Result: There are multiple -13 diagnostic codes active.
F. Use the electronic service tool to monitor active diagnostic
codes or recently logged diagnostic codes. Look for an active Proceed to Test Step 3.
or logged -13 code for a pressure sensor or the barometric
pressure sensor. Result: There is an active -13 diagnostic code for only
one sensor.
G. Turn the keyswitch to the OFF position.
Proceed to Test Step 4.

2. Ensure that the Systems are Fully Thawed Diagnostic codes Result: There are no active -13 codes.

A. Move the machine into an environment where the ambient Repair: The fault was caused by ice in the system that
temperature is greater than 5° C (41° F) during any has now been thawed. Return the unit to service
troubleshooting.
Result: There are multiple -13 diagnostic codes active.
B. If engine has been operated or stored in cold ambient con-
ditions where there is a risk of ice formation on a sensor or Proceed to Test Step 3.
sensor pipes, run engine until the coolant temperature ex-
ceeds 65° C (149° F) for 20 minutes. Result: A single -13 code is active or logged.

C. Turn the keyswitch to the OFF position. Wait for at least 20 Proceed to Test Step 4.
seconds. The electronic service tool will disconnect.

D. Turn the keyswitch to the ON position.

E. Verify that coolant temperature, intake manifold air temper-

ature, and NRS temperature are all now at least 5° C (41° F).

F. Check for active -13 diagnostic codes.

G. Check that the suspect sensor is installed correctly. Check

that the suspect sensor is fully seated into the engine.

(continued)

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(Table 187, contd)

Troubleshooting Test Steps Values Results

3. Check the Barometric Pressure Sensor Barometric pressure Result: There is no active -13 code. The fault was
sensor fault caused by a faulty barometric pressure sensor.
A. Turn the keyswitch to the OFF position.
Use the electronic service tool to clear all logged codes.
B. Install a new Electronic Control Module (ECM). Return the unit to service.

Note: The Barometric Pressure Sensor is located within the Result: A -13 code is active.
ECM so cannot be replaced separately. To replace the Baro-
metric Pressure Sensor, the ECM must be replaced. Proceed to Test Step 4.

C. Turn the keyswitch to the ON position. Do not start the

engine.

Note: Wait at least 10 seconds in order for the diagnostic co-

des to become active.

D. Monitor the status parameter for the suspect sensor on the

electronic service tool.

4. Check the Suspect Pressure Sensor Barometric pressure Result: There is an active -13 code or the sensor is
sensor fault blocked
A. Turn the keyswitch to the OFF position.
Temporarily connect a new sensor to the harness. Use
B. Disconnect the connector for the suspect sensor and re- the electronic service tool to confirm that the repair elimi-
move the sensor from the engine. nates the fault.

C. Check the sensor for a blockage. If the fault is eliminated, permanently install the new sen-
sor. Refer to Disassembly & Assembly for the correct in-
D. Temporarily reconnect the sensor to the harness. Do not in- stallation procedure.
stall the sensor on the engine.
If the fault is still present, proceed to Test Step 3.
E. Turn the keyswitch to the ON position. Do not start the
engine. Result: There is no active -13 code.

F. Check for an active -13 diagnostic code for the suspect Use the electronic service tool to clear all logged codes.
sensor.

i08368355

Sensor (Data Link Type) - Test

Use this procedure to troubleshoot the electrical

system if a fault is suspected with the CAN data link
sensors. Also use this procedure if a diagnostic code
in Table 188 is active or easily repeated.

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Table 188
Diagnostic Trouble Codes for the Data Link Sensors

J1939 Code Code Description Comments

The data received from the NOx sensor is out of range.
3216-12 Aftertreatment #1 Intake NOx : Failure The code is logged.
The warning lamp is illuminated.

The data received from the NOx sensor is out of range.

3226-12 Aftertreatment #1 Outlet NOx : Failure The code is logged.
The warning lamp is illuminated.

The data received from the Diesel Oxidation Catalyst (DOC)/Diesel Particulate
Aftertreatment Diesel Particulate Filter Filter (DPF) inlet temperature sensor is out of range.
5742–12
Temperature Sensor Module : Failure The code is logged.
The warning lamp is illuminated.

The data received from the Selective Catalytic Reduction (SCR) inlet tempera-
Aftertreatment 1 SCR Temperature ture sensor is out of range.
5743–12
Sensor Module : Failure The code is logged.
The warning lamp is illuminated.

If the electronic service tool will not communicate

with the ECM, refer to Troubleshooting, “Electronic
Service Tool Does Not Communicate” before starting
this procedure. The procedure verifies that electrical
power is being supplied to the ECM and to the
diagnostic connector.
The data links are used to communicate information
between the engine ECM and other control modules
that are a part of the application. The electronic
service tool also communicates with the ECM via the
data links.
The diagnostic connector contains connections for
electrical power and for the data links.
When the keyswitch is in the OFF position, the
electronic service tool may communicate with the
ECM. However, the communications may be
disrupted and the communications may require
frequent reconnection. To avoid any disruption, place
the keyswitch in the ON position when the electronic
service tool is being used.
The electronic service tool may display the following
error message:
“The version of the ECM is not recognized and the
integrity of the changed parameters and displayed
data is not guaranteed.”
This message indicates that one of the following
conditions exists:

• The flash file in the ECM is newer than the version

of the electronic service tool.

• The latest version of the electronic service tool has

not been installed.

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Illustration 52 g06498378
Schematic for the data-type sensors
Not all connectors are shown. Refer to the appropriate Electrical Schematic.

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the sensor connectors and
the ECM connectors.
Note: Some engines are equipped with a triple-probe
sensor for the DOC, the DPF, and the SCR inlet
temperatures. Refer to the Electrical Schematic for
the application.
Some engines are equipped with a dual-probe
sensor for the DOC and DPF inlet temperatures and
a single-probe sensor for the SCR inlet temperature.
Refer to the Electrical Schematic for the application.
Complete the procedure in the order in which the
steps are listed.

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 M0095947-10 317
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Table 189
Troubleshooting Test Steps Values Results

1. Check the Connectors Connectors Result: The connectors were connected correctly and did
not have corrosion or moisture.
A. Thoroughly inspect the connectors that are associated with the
data link circuits. Verify that the connectors are free of debris, free Proceed to Test Step 2.
of corrosion, and securely connected.
Result: The connectors were not connected correctly or
B. Perform a 45 N (10 lb) pull test on all the wires associated with the connectors have corrosion or moisture.
the data link circuits.
Repair: Repair the connectors and/or the wiring. Replace
parts, if necessary.
Proceed to Test Step 3.

2. Check for Active or Recently Logged Diagnostic Codes Diagnostic Trou- Result: There is an active or recently logged 3216-12 di-
ble Codes agnostic code.
A.Establish communication between the electronic service tool
and the engine Electronic Control Module (ECM). Refer to Trou- Repair: Install a replacement NOx sensor. Refer to Disas-
bleshooting, “Electronic Service Tools” sembly and Assembly for the correct procedure.
Proceed to Test Step 3.
B. Look for active or logged codes.
Result: There is an active or recently logged 3226-12 di-
agnostic code.

Repair: Install a replacement NOx sensor. Refer to Disas-

sembly and Assembly for the correct procedure.
Proceed to Test Step 3.

Result: There is an active or recently logged 5742–12 di-

agnostic code.

Repair: Install a replacement DPF/DOC inlet temperature

sensor. Refer to Disassembly and Assembly, Tempera-
ture Sensor (Exhaust) - Remove and Install (Temperature
Sensor for Diesel Oxidation Catalyst (DOC), Diesel Par-
ticulate Filter (DPF), and (Selective Catalyst Reduction
(SCR)).
Proceed to Test Step 3.

Result: There is an active or recently logged 5743–12 di-

agnostic code.

Repair: Install a replacement SCR inlet temperature

sensor.
Proceed to Test Step 3.

3. Perform the “ Aftertreatment System Functional Test”” Diagnostic Result: The test passed and no diagnostic codes became
Codes active.
A. Turn the keyswitch to the ON position.
Return the engine to service.
B. Use the electronic service tool to perform the “Aftertreatment
System Functional Test” . Result: The test failed.

Troubleshoot any diagnostic codes that became active

during the test. Refer to Troubleshooting “Diagnostic
Trouble Codes”.

If the procedure did not correct the fault, contact the Deal-
er Solutions Network (DSN).

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i07575170

Sensor Signal (Analog, Active

- Test

This procedure covers the following diagnostic

codes:
Table 190
Diagnostic Codes for the Active Analog Sensors

J1939 Code Code Description Comments

The ECM detects that the barometric pressure sensor has failed.
108-12 Barometric Pressure : Failure
The code is logged.

The ECM detects that the signal voltage for the fuel rail pressure sensor is greater than
Fuel Rail Pressure Sensor : Volt-
157-3 4.7 V for 0.6 seconds.
age Above Normal
The code is logged.

The ECM detects that the signal voltage for the fuel rail pressure sensor is less than 0.3
Fuel Rail Pressure Sensor : Volt-
157-4 V for 0.6 seconds.
age Below Normal
The code is logged.

The ECM detects that the fuel rail pressure sensor has failed.
157-12 Fuel Rail Pressure Sensor : Failure
The code is logged.

The ECM detects that the signal voltage for the NRS differential pressure sensor is
EGR Differential Pressure Sensor :
411-3 greater than 4.8 V for 1 second.
Voltage Above Normal
The code is logged.

The ECM detects that the signal voltage for the NRS differential pressure sensor is less
EGR Differential Pressure Sensor :
411-4 than 0.1 V for 1 second.
Voltage Below Normal
The code is logged.

Auxiliary Pressure #1 : Voltage The ECM detects a signal voltage that is not in the acceptable range.
1387–3
Above Normal
Auxiliary Pressure #1 : Voltage Be- The ECM detects a signal voltage that is not in the acceptable range.
1387–4
low Normal
The ECM detects that the signal voltage for the DPF differential pressure sensor is
Aftertreatment #1 DPF Differential
3251–3 greater that 4.8 V for 8 seconds.
Pressure : Voltage Above Normal
The code is logged.

The ECM detects that the signal voltage for the DPF differential pressure sensor is less
Aftertreatment #1 DPF Differential
3251–4 than 0.2 V for 8 seconds.
Pressure : Voltage Below Normal
The code is logged.

The ECM detects that the signal voltage for the NRS intake pressure sensor is greater
EGR Intake Pressure Sensor : Volt-
3358-3 than 4.8 V for 0.25 seconds.
age Above Normal
The code is logged.

The ECM detects that the signal voltage for the NRS intake pressure sensor is less than
EGR Intake Pressure Sensor : Volt-
3358-4 0.4 V for 0.25 seconds.
age Below Normal
The code is logged.

The ECM detects that the signal voltage for the intake manifold air pressure sensor is
Intake Manifold Pressure Sensor :
3563-3 greater than 4.8 V for 1 second.
Voltage Above Normal
The code is logged.

The ECM detects that the signal voltage for the intake manifold air pressure sensor is
Intake Manifold Pressure Sensor :
3563-4 less than 0.4 V for 1 second.
Voltage Below Normal
The code is logged.

(continued)

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(Table 190, contd)

Diagnostic Codes for the Active Analog Sensors

J1939 Code Code Description Comments

The ECM detects that the signal voltage for the DPF intake pressure sensor is greater
DPF #1 Intake Pressure : Voltage
3609–3 than 4.8 V for 6 seconds.
Above Normal
The code is logged.

The ECM detects that the signal voltage for the DPF intake pressure sensor is less than
DPF #1 Intake Pressure : Voltage
3609–4 0.2 V for 6 seconds.
Below Normal
The code is logged.

Follow the troubleshooting procedure to identify the root cause of the fault.

The following conditions must exist before any of the

above codes will become active:

• There are no active 3509 or 3510 codes.

• There are no active 168 codes.
The following background information is related
to this procedure:
The 5 VDC sensor supply provides power to all 5
VDC sensors. The sensor supply is output short
circuit protected. A short circuit to the battery will not
damage the circuit inside the ECM.
Pull-up Voltage
The ECM continuously outputs a pull-up voltage on
the circuit for the sensor signal wire. The ECM uses
this pull-up voltage to detect an open in the signal
circuit. When the ECM detects a voltage above a
threshold on the signal circuit, an open circuit
diagnostic code (XXXX-3) is generated for the
sensor.
If the sensor is disconnected, pull-up voltage
indicates that the wires from the sensor connector to
the ECM are not open or shorted to ground. If the
sensor is disconnected, the absence of pull-up
voltage indicates an open in the signal wire or a short
to ground. If the sensor is disconnected and the
voltage is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.

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Illustration 53 g06366785
Schematic diagram for the active sensors

Note: Refer to the Electrical Schematic for the

application for the wiring information for the auxiliary
pressure sensor.

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Table 191
Troubleshooting Test Steps Values Results

1. Download Information Using the Electronic Service Tool Downloaded Result: The information was successfully saved.
information
A. Use the electronic service tool to download the “Product Status Proceed to Test Step 2.
Report” (PSR) with histograms before performing any troubleshoot-
ing or clearing any diagnostic codes. Result: The electronic service tool information was not
successfully saved.
Note: The downloaded information will be required by the Dealer Sol-
utions Network (DSN) if troubleshooting assistance is required. Contact the Dealer Solutions Network (DSN) for
guidance.

2. Create an Electronic Service Tool Snapshot (only applicable Snapshot Result: The electronic service tool snapshot was suc-
to 157–3 and 157–4 diagnostic codes) saved cessfully saved.

A. Select “Snapshot Viewer” on the electronic service tool, using me- Proceed to Test Step 3.
nus: Information -> Snapshot -> Viewer
Result: The electronic service tool snapshot was not
B. Select the event code and then click “View Graph” . successfully saved.

C. Select the following parameter and then click OK. Contact the DSN for guidance.

· Engine Speed

D. Select Save to "File to save" a Snapshot File (*.xml). This file will
contain all the data in the snapshot and not only the data shown on
the graph.
Note: The downloaded information will be required by the DSN if
troubleshooting assistance is required.

3. Check for Diagnostic Codes Diagnostic Result: There are no active diagnostic codes for the
code active sensors.
A. Establish communication between the electronic service tool and
the ECM . Refer to Troubleshooting, “Electronic Service Tools”, if Repair: If there are logged diagnostic codes for the ac-
necessary. tive sensors, the fault may be intermittent.

B. Turn the keyswitch to the ON position. Refer to Troubleshooting, “Electrical Connectors - In-
spect” to identify intermittent faults.
C. Look for active or logged diagnostic codes for the active sensors.
Result: A diagnostic code that is listed in Table 190 is
active.

Proceed to Test Step 4.

4. Check the 5 VDC Supply Voltage at the Sensor Connector Test passed Result: The supply voltage is approximately 5.0 ± 0.2
VDC
A. Turn the keyswitch to the ON position.
Connect the sensor and then proceed to Test Step 5.
B. Measure the voltage between the sensor supply pin and the sen-
sor return pin at the suspect sensor. Result: The supply voltage is not approximately 5.0 ±
0.2 VDC.

The fault is in the 5 V supply wiring to the suspect sen-

sor. Repair the wiring or replace the harness

Verify that the problem is resolved.

(continued)

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(Table 191, contd)

Troubleshooting Test Steps Values Results

5. Check the Type of Diagnostic Code that is Active Diagnostic Result: A 157-12 diagnostic code is active.
codes
A. Turn the keyswitch to the ON position. Wait at least 60 seconds for Repair: Replace the fuel rail pressure sensor.
activation of the diagnostic codes. Note: Do not replace the fuel rail pressure sensor if the
157-12 diagnostic code is logged. Only replace the sen-
B. Use the electronic service tool to check for active diagnostic co- sor for an active 157-12 diagnostic code.
des. Record all active diagnostic codes.
Use the electronic service tool to clear all logged diag-
nostic codes. Return the unit to service.

If the fault is still present, contact the Dealer Solutions

Network (DSN).

Result: A 108–12 diagnostic code is active.

Repair: Install a replacement ECM.

Use the electronic service tool to clear all logged diag-
nostic codes. Return the unit to service.
Result: A -3 diagnostic code is active for one or more
of the active sensors.

Proceed to Test Step 8.

Result: A -4 diagnostic code is active for one or more

of the active sensors.

Proceed to Test Step 9.

6. Create a Short at the Sensor Connector Short created Result: A -4 diagnostic code became active after creat-
ing the short at the sensor connector.
A. Turn the keyswitch to the OFF position.
Repair: The wiring is OK. Replace the sensor.
B. Disconnect the connector for the suspect sensor. Verify that the problem is resolved.

C. Use a jumper wire to create a short between the signal terminal Result: A -4 diagnostic code does not become active
and the ground terminal at the sensor connector. for the suspect sensor.

D. Turn the keyswitch to the ON position. Proceed to Test Step 7.

E. Monitor the diagnostic codes on the electronic service tool. Check

for an active -4 diagnostic code for the suspect sensor.

F. Turn the keyswitch to the OFF position.

(continued)

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(Table 191, contd)

Troubleshooting Test Steps Values Results

7. Create a Short Circuit at the Engine Interface Connector Short created Result: A -4 diagnostic code became active after creat-
ing the short at the engine interface connector.
A. Turn the keyswitch to the OFF position.
Repair: The fault is in the engine wiring harness. Re-
B. Disconnect the engine interface connector. pair the harness or replace the harness.
Verify that the problem is resolved.
C. Use a jumper wire to create a short between the signal terminal
and the ground terminal at the engine interface connector. Result: A -4 diagnostic code does not become active
for the suspect sensor.
D. Turn the keyswitch to the ON position.
Proceed to Test Step 8.
E. Monitor the diagnostic codes on the electronic service tool. Check
for an active -4 diagnostic code for the suspect sensor.

Note: Diagnostic codes for all the engine sensors will be active with
the engine interface connector disconnected. Disregard the other di-
agnostic codes. Only look for codes for the suspect sensor.

F. Turn the keyswitch to the OFF position.

8. Check the Wiring Between the Engine Interface Connector Less than 2 Result: The resistance is greater than 2 Ohms - There
and the ECM for an Open Circuit Ohms is a fault in the wiring between the engine interface con-
nector and the P1/P2 connector.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty
B. Disconnect the engine interface connector. Disconnect the P1/P2 wiring.
connector from the ECM. Refer to Illustration 53 for the correct
connector. Verify that the repair eliminates the fault.

C. Thoroughly inspect the P1/J1 or P2/J2 ECM connectors. Refer to Result: All measured resistances are less than 2
Troubleshooting, Electrical Connectors - Inspect. Ohms.

D. Use a suitable multimeter to measure the resistance between the Proceed to Test Step 12.
sensor signal terminal on the engine interface connector and the sen-
sor signal terminal on the P1/P2 connector.

9. Create an Open at the Suspect Sensor Connector Create an Result: A -3 diagnostic code became active after dis-
Open connecting the sensor.
A. Turn the keyswitch to the OFF position.
The wiring is OK. Replace the sensor.
B. Disconnect the sensor connector of the suspect sensor with the
active -4 diagnostic code. Verify that the problem is resolved.

C. Turn the keyswitch to the ON position. Result: A -3 diagnostic code did not become active
after disconnecting the sensor.
D. Monitor the diagnostic codes on the electronic service tool. Check
for an active -3 diagnostic code for the suspect sensor. Proceed to Test Step 10.

E. Turn the keyswitch to the OFF position.

(continued)

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(Table 191, contd)

Troubleshooting Test Steps Values Results

10. Create an Open at the Engine Interface Connector Create an Result: A -3 diagnostic code became active for the sus-
Open pect sensor after disconnecting the engine interface
A. Turn the keyswitch to the OFF position. connector.

B. Disconnect the engine interface connector. Repair: The fault is in the engine wiring harness. Re-
pair the engine wiring harness or replace the engine
C. Turn the keyswitch to the ON position. wiring harness.

D. Monitor the diagnostic codes on the electronic service tool. Check Verify that the problem is resolved.
for an active -3 diagnostic code for the suspect sensor.
Note: Diagnostic codes for all the engine sensors will be active with Result: A -3 diagnostic code did not become active
the engine interface connector disconnected. Disregard the other di- after disconnecting the engine interface connector.
agnostic codes. Only look for codes for the suspect sensor.
Proceed to Test Step 11.
E. Turn the keyswitch to the OFF position.

11. Check the Wiring Between the Engine Interface Connector Greater than 1k Result: At least one of the resistance measurements is
and the ECM for a Short Circuit Ohm less than 1 k Ohm. The fault is in the wiring connected
to the ECM connector.
A. Turn the keyswitch to the OFF position.
B. Disconnect the engine interface connector. Disconnect the P1/P2 Repair: Repair the faulty wiring or replace the faulty
connector from the ECM. Refer to Illustration 53 for the correct wiring.
connector.
Result: All resistance measurements are greater than
C. Thoroughly inspect the P1/J1 or P2/J2 ECM connectors. Refer to 1 k Ohm.
Troubleshooting, Electrical Connectors - Inspect.
Proceed to Test Step 12.
D. Use a suitable multimeter to measure the resistance between the
suspect signal terminal on the engine interface connector (ECM side)
and all other terminals on the engine interface connector.

12. Perform the Wiggle Test Test passed Result: The wiring failed the Wiggle Test.

Carefully following this procedure is the best way to identify the root There is a problem with the wiring. Repair the wiring or
cause of an intermittent problem. replace the wiring.

A. Turn the keyswitch to the ON position. Verify that the problem is resolved.

B. Use the electronic service tool to run the “Wiggle Test” . STOP

C. Slowly wiggle the wiring and the connectors between the P2 con- Result: The wiring passed the Wiggle Test.
nector and the sensor. Pay particular attention to the wiring near each
connector. Be sure to wiggle all the wiring. The problem may be intermittent. Inspect the wiring.
As you wiggle the wiring look for these problems. Refer to Troubleshooting, “Electrical Connectors -
1. Loose connectors or damaged connectors Inspect”.
2. Moisture on the connectors or the wiring
3. Damaged that is caused by excessive heat If the wiring looks OK, perform the following procedure.
4. Damage that is caused by chafing
5. Improper routing of wiring 1. Turn the keyswitch to the OFF position.
6. Damaged insulation 2. Disconnect the connectors. Carefully inspect the ter-
minals for proper installation. Make sure that each ter-
minal is clean and dry.
3. Insert a pin into each socket. Verify that each socket
grips the pin firmly. Repair any problems.
4. Connect all connectors.
5. Verify that the problem is resolved.
6. Return the unit to service.
STOP

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i07988012

Sensor Signal (Analog,

Passive) - Test

This procedure covers the following diagnostic

codes:
Table 192
Diagnostic Trouble Codes for Analog Passive Sensors

J1939 Code Code Description Comments

Engine Intake Manifold #1 Temper- The Electronic Control Module (ECM) detects that the signal voltage for the intake mani-
105-3
ature : Voltage Above Normal fold temperature sensor is greater than 4.975 V for 8 seconds.

Engine Intake Manifold #1 Temper- The ECM detects that the signal voltage for the intake manifold temperature sensor is
105-4
ature : Voltage Below Normal less than 0.12 V for 8 seconds.

Engine Coolant Temperature : Volt- The ECM detects that the signal voltage for the coolant temperature sensor is greater
110-3
age Above Normal than 4.95 V for 8 seconds.

Engine Coolant Temperature : Volt- The ECM detects that the signal voltage for the coolant temperature sensor is less than
110-4
age Below Normal 0.2 V for 8 seconds.

Engine Air Inlet Temperature : Volt- The ECM detects that the signal voltage for the air inlet temperature sensor is greater
172-3
age Above Normal than 4.95 V for 8 seconds.

Engine Air Inlet Temperature : Volt- The ECM detects that the signal voltage for the air inlet temperature sensor is less than
172-4
age Below Normal 0.2 V for 8 seconds.

Engine Fuel Temperature 1 : Volt- The ECM detects that the signal voltage for the fuel temperature sensor is greater than
174-3
age Above Normal 4.975 V for 8 seconds

Engine Fuel Temperature 1 : Volt- The ECM detects that the signal voltage for the fuel temperature sensor is less than 0.2
174-4
age Below Normal V for 8 seconds.

Transmission Oil Temperature : The ECM detects voltage that is below the acceptable range.
177–3
Voltage Above Normal

Transmission Oil Temperature : The ECM detects voltage that is below the acceptable range.
177–4
Voltage Below Normal

Engine Exhaust Gas Recirculation The ECM detects that the signal voltage for the NRS temperature sensor is greater than
412-3 Temperature : Voltage Above 4.975 V for 8 seconds.
Normal
Engine Exhaust Gas Recirculation The ECM detects that the signal voltage for the NRS temperature sensor is less than
412-4 Temperature : Voltage Below 0.125 V for 8 seconds.
Normal
Auxiliary Temperature #1 : Voltage The ECM detects voltage that is above the acceptable range.
441–3
Above Normal
Auxiliary Temperature #1 : Voltage The ECM detects voltage that is below the acceptable range.
441–4
Below Normal
Engine Charge Air Cooler Outlet The ECM detects voltage that is above the acceptable range.
2630–3 Temperature : Voltage Above
Normal
Engine Charge Air Cooler Outlet The ECM detects voltage that is below the acceptable range.
2630–4 Temperature : Voltage Below
Normal

(continued)

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(Table 192, contd)

Diagnostic Trouble Codes for Analog Passive Sensors

J1939 Code Code Description Comments

EGR Cooler Inlet Temperature : The ECM detects that the signal voltage for the NRS cooler inlet temperature sensor is
4750–3
Voltage Above Normal greater than 4.975 V for 8 seconds.

EGR Cooler Inlet Temperature : The ECM detects that the signal voltage for the NRS cooler inlet temperature sensor is
4750–4
Voltage Below Normal less than 0.2 V for 8 seconds.

Follow the troubleshooting procedure to identify the root cause of the fault.

Note: The following conditions must exist before any If the sensor is disconnected, pull-up voltage at the
of the above codes will become active: connector indicates that the wires are not open or
shorted to ground. If the sensor is disconnected, the
• The ECM has been powered for at least 2 absence of pull-up voltage indicates an open in the
seconds. signal wire or a short to ground. If the sensor is
disconnected and the voltage is different from pull-up
• There are no active 168-X diagnostic codes. voltage, the signal wire is shorted to another wire in
the harness.
The ECM will log the diagnostic code. If equipped,
the warning light will come on.
This procedure covers open circuit diagnostic codes
and short circuit diagnostic codes that are associated
with the following sensors that are connected to the
ECM:
• Coolant temperature sensor

• Intake manifold air temperature sensor

• Fuel temperature sensor
• Air inlet temperature sensor

• Exhaust Gas Recirculation (EGR) pre-cooler

temperature sensor

• EGR post-cooler temperature sensor

The following background information is related
to this procedure:
The temperature sensors have two terminals. The
signal line is connected to each sensor connector
terminal 1. Terminal 2 is the return line. The signal
voltage from terminal 1 of each sensor is supplied to
the appropriate terminal in the ECM.
Pull-up Voltage
The ECM continuously outputs a pull-up voltage on
the circuit for the sensor signal wire. The ECM uses
this pull-up voltage to detect an open in the signal
circuit. When the ECM detects a voltage above a
threshold on a signal circuit, an open circuit
diagnostic code (XXX-3) is communicated to the
engine ECM.

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 M0095947-10 327
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Illustration 54 g06498425
Schematic diagram for the engine temperature sensors

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for more
information.
Note: Refer to the Electrical Schematic for the
application for the wiring information for the auxiliary
pressure sensor and the transmission oil temperature
sensor (if equipped).

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 328 M0095947-10
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Table 193
Troubleshooting Test Steps Values Results

1. Download Information Using the Electronic Service Downloaded Result: The information was successfully saved.
Tool information
Proceed to Test Step 2.
A. Use the electronic service tool to download the “Product
Status Report” (PSR) with histograms before performing any Result: The electronic service tool information was not suc-
troubleshooting or clearing any diagnostic codes. cessfully saved.

Note: The downloaded information will be required by the Contact the Dealer Solutions Network (DSN) for guidance.
Dealer Solutions Network (DSN) if troubleshooting assistance
is required.

2. Create an Electronic Service Tool Snapshot (only appli- Snapshot saved Result: The electronic service tool snapshot was success-
cable to 174–3 and 174–4 diagnostic codes) fully saved.

A. Select “Snapshot Viewer” on the electronic service tool, us- Proceed to Test Step 3.
ing menus: Information -> Snapshot -> Viewer
Result: The electronic service tool snapshot was not suc-
B. Select the event code and then click “View Graph” . cessfully saved.

C. Select the following parameter and then click OK. Contact the DSN for guidance.

· Engine Speed

D. Select Save to "File to save" a Snapshot File (*.xml). This

file will contain all the data in the snapshot and not only the da-
ta shown on the graph.
Note: The downloaded information will be required by the
DSN if troubleshooting assistance is required.

3. Check for Diagnostic Trouble Codes Codes Result: A -3 diagnostic code is active.

A. Connect to the electronic service tool. Proceed to Test Step 4.

B. Turn the keyswitch to the ON position. Result: A —4 diagnostic code is active.

C. Access the “Active Diagnostic Code” screen on the elec- Proceed to Test Step 7.
tronic service tool. Result: For a diagnostic code that is logged but not cur-
rently active, Proceed to Test Step 10.
Wait at least 30 seconds in order for the diagnostic codes
to become active.

D. Look for one of the diagnostic codes that are listed in Table
192 .

(continued)

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(Table 193, contd)

Troubleshooting Test Steps Values Results

4. Create a Short at the Sensor Connector Short Circuit Result: A -4 diagnostic code became active after creating
Recognized the short at the sensor connector.
A. Turn the keyswitch to the OFF position.
Repair: The wiring is OK. Replace the sensor.
B. Disconnect the suspect sensor.
Verify that the problem is resolved.
C. Use a jumper wire to create a short between the signal ter-
minal and the ground terminal at the sensor connector. Result: The -3 diagnostic code remains active for the sus-
pect sensor.
D. Turn the keyswitch to the ON position.
Repair: Proceed to Test Step 5.
E. Monitor the diagnostic codes on the electronic service tool.
Check for an active -4 diagnostic code for the suspect sensor.

Wait at least 30 seconds in order for the diagnostic codes

to become active.

F. Turn the keyswitch to the OFF position.

5. Create a Short Circuit at the Engine Interface Short created Result: A -4 diagnostic code became active after creating
Connector the short at the engine interface connector.

Note: This Test Step is not applicable to the air inlet tempera- Repair: The fault is in the engine wiring harness. Repair the
ture sensor or the ATAAC outlet temperature sensor. If the harness or replace the harness.
suspect sensor is the air inlet temperature sensor or the Verify that the problem is resolved.
ATAAC outlet temperature sensor, proceed to Test Step 4.
Result: A -4 diagnostic code does not become active for the
A. Turn the keyswitch to the OFF position. suspect sensor.

B. Disconnect the engine interface connector. Proceed to Test Step 6.

C. Use a jumper wire to create a short between the signal ter-

minal and the ground terminal at the engine interface
connector.

D. Turn the keyswitch to the ON position.

E. Monitor the diagnostic codes on the electronic service tool.

Check for an active -4 diagnostic code for the suspect sensor.

Note: Diagnostic codes for all the engine sensors will be ac-
tive with the engine interface connector disconnected. Disre-
gard the other diagnostic codes. Only look for codes for the
suspect sensor.

F. Turn the keyswitch to the OFF position.

(continued)

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(Table 193, contd)

Troubleshooting Test Steps Values Results

6. Check the Wiring to the ECM for an Open Circuit Less than 2 Result: The resistance is greater than 2 Ohms - There is a
Ohms fault in the wiring to the P1/P2 connector.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty wiring.
B. Disconnect the engine interface connector. Disconnect the
P1/P2 connector from the ECM. Refer to Illustration 54 for the Verify that the repair eliminates the fault.
correct connector.
Note: If the suspect sensor is the air inlet temperature sensor, Result: All measured resistances are less than 2 Ohms.
disconnect the P1 connector and the sensor connector.
Proceed to Test Step 10.
C. Thoroughly inspect the P1/J1 or P2/J2 ECM connectors.
Refer to Troubleshooting, Electrical Connectors - Inspect.

D. Use a suitable multimeter to measure the resistance be-

tween the sensor signal terminal on the engine interface con-
nector and the sensor signal terminal on the P1/P2 connector.
Note: For the air inlet temperature sensor, measure the resist-
ance between terminal 1 on the sensor connector and P1:24.

7. Create an Open at the Suspect Sensor Connector Open Circuit Result: A -3 diagnostic code became active after discon-
Recognized necting the sensor.
A. Turn the keyswitch to the OFF position.
Repair: The wiring is OK. Replace the sensor.
B. Disconnect the sensor connector of the suspect sensor with
the active -4 diagnostic code. Verify that the problem is resolved.

C. Turn the keyswitch to the ON position. Result: The -4 or diagnostic code remains active for the sus-
pect sensor.
D. Monitor the diagnostic codes on the electronic service tool.
Check for an active -3 diagnostic code for the suspect sensor. Repair: Proceed to Test Step 8.

Wait at least 30 seconds in order for the diagnostic codes

to become active.
· For a 110-3 code, start the engine and let the engine idle
for 7 minutes. The engine must be running for at least 7
minutes in order for the diagnostic to run.

E. Turn the keyswitch to the OFF position.

(continued)

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(Table 193, contd)

Troubleshooting Test Steps Values Results

8. Create an Open Circuit at the Engine Interface Create an Open Result: A -3 diagnostic code became active for the suspect
Connector sensor after disconnecting the engine interface connector.

Note: This Test Step is not applicable to the air inlet tempera- Repair: The fault is in the engine wiring harness. Repair the
ture sensor or the ATAAC outlet temperature sensor. If the engine wiring harness or replace the engine wiring harness.
suspect sensor is the air inlet temperature sensor or the
ATAAC outlet temperature sensor, proceed to Test Step 9. Verify that the problem is resolved.

A. Turn the keyswitch to the OFF position. Result: A -3 diagnostic code did not become active after dis-
connecting the engine interface connector.
B. Disconnect the engine interface connector.
Proceed to Test Step 9.
C. Turn the keyswitch to the ON position.

D. Monitor the diagnostic codes on the electronic service tool.

Check for an active -3 diagnostic code for the suspect sensor.
Note: Diagnostic codes for all the engine sensors will be ac-
tive with the engine interface connector disconnected. Disre-
gard the other diagnostic codes. Only look for codes for the
suspect sensor.

E. Turn the keyswitch to the OFF position.

9. Check the Wiring to the ECM for a Short Circuit Greater than 1k Result: At least one of the resistance measurements is less
Ohm than 1 k Ohm. The fault is in the wiring connected to the
A. Turn the keyswitch to the OFF position. ECM connector.

B. Disconnect the engine interface connector. Disconnect the Repair: Repair the faulty wiring or replace the faulty wiring.
P1/P2 connector from the ECM. Refer to Illustration 54 for the
correct connector. Result: All resistance measurements are greater than 1 k
Ohm.
C. Thoroughly inspect the P1/J1 or P2/J2 ECM connectors.
Refer to Troubleshooting, Electrical Connectors - Inspect. Proceed to Test Step 10.

D. Use a suitable multimeter to measure the resistance be-

tween the suspect signal terminal on the engine interface con-
nector (ECM side) and all other terminals on the engine
interface connector.
Note: For the air inlet temperature sensor, measure the resist-
ance between P1:24 and all other terminals on the P1
connector.

(continued)

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(Table 193, contd)

Troubleshooting Test Steps Values Results
Wiggle test
10. Perform the Wiggle Test Result: The wiring failed the Wiggle Test.

Carefully following this procedure is the best way to identify Repair: There is a problem with the wiring. Repair the wiring
the root cause of an intermittent problem. or replace the wiring.

A. Turn the keyswitch to the ON position. Verify that the problem is resolved.

B. Use the electronic service tool to run the “Wiggle Test” . Result: The wiring passed the Wiggle Test.

C. Slowly wiggle the wiring and the connectors between the Repair: The problem may be intermittent. Inspect the wiring.
P2 connector and the sensor. Slowly wiggle the wiring and the Refer to Troubleshooting, “Electrical Connectors - Inspect”.
connectors between the P1 connector and the sensor. Pay
particular attention to the wiring near each connector. Be sure If the wiring looks OK, perform the following procedure.
to wiggle all the wiring.
1. Turn the keyswitch to the OFF position.
D. As you wiggle the wiring look for these problems.
2. Disconnect the connectors. Carefully inspect the terminals
1. Loose connectors or damaged connectors for proper installation. Make sure that each terminal is clean
and dry.
2. Moisture on the connectors or the wiring
3. Insert a pin into each socket. Verify that each socket grips
3. Damage that is caused by excessive heat the pin firmly. Repair any problems.

4. Damage that is caused by chafing 4. Connect all connectors.

5. Improper routing of wiring 5. Verify that the problem is resolved.

6. Damaged insulation 6. Return the unit to service.

If the procedure did not correct the fault, contact the Dealer Solutions Network (DSN).

i08368277

Sensor Supply - Test

This procedure covers the following diagnostic

codes:

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Table 194
Diagnostic Trouble Codes for Sensor Supplies

J1939
Code Code Description Comments
3509-3 Sensor Supply Voltage 1 : Voltage Above Normal The Electronic Control Module (ECM) detects the following conditions:

3510-3 Sensor Supply Voltage 2 : Voltage Above Normal The 5 VDC supply for the sensors is greater than 5.16 VDC for more than
2 seconds.

There are no active battery supply faults.

The warning lamp will come on. The ECM sets all the sensors on the 5
VDC circuit to the default values.
The engine will be derated.

3509-4 Sensor Supply Voltage 1 : Voltage Below Normal The ECM detects the following conditions:

3510-4 Sensor Supply Voltage 2 : Voltage Below Normal The 5 VDC supply for the sensors is less than 4.84 VDC for more than 2
seconds.

There are no active battery supply faults.

The warning lamp will come on. The ECM sets all the sensors on the 5
VDC circuit to the default values.
The engine will be derated.

Note: A 3509-XX diagnostic code indicates a fault • Fan speed sensor

in the 5 VDC circuit on J1:34, J2:36, or J2:67. A
3510-XX diagnostic code indicates a fault in the 5 • Aftertreatment temperature sensor
VDC circuit on J1:35, J2:41, J2:68, J2:69.
• Fuel rail pressure sensor
The following background information is related
to this procedure: A diagnostic code can be caused by the following
conditions:
The ECM supplies regulated +5 VDC to the following
sensors. A 3510 diagnostic code will become active if • A short circuit in the harness
a fault is detected on this circuit:
• A faulty sensor
• EGR valve position sensor
• An open circuit in the harness
• Turbocharger electronic wastegate position
sensor Note: Refer to the Electrical Schematic for detailed
wiring information for the sensors on the 5 V
• Intake throttle valve position sensor supplies.

• Analog accel pedal #1 position (if equipped) Complete the procedure in the order in which the
steps are listed.
• Diesel Exhaust Fluid (DEF) pressure sensor

• Intake manifold air pressure sensor

• NRS intake and differential pressure sensor
• Diesel Particulate Filter (DPF) intake and
differential pressure sensor
• Secondary speed/timing sensor
The ECM supplies regulated +5 VDC to the following
sensors. A 3509 diagnostic code will become active if
a fault is detected on this circuit:
• Primary speed/timing sensor

• Analog accel pedal #2 position (if equipped)

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Table 195
Troubleshooting Test Steps Values Results

1. Determine the Code Diagnostic Result: A -3 or -4 code is present.

Codes
A. Connect the electronic service tool to the service tool connector. Note which sensor supply has the active diagnostic code.
Refer to Troubleshooting, “Electronic Service Tools”, if necessary.
Proceed to Test Step 2.
B. Turn the keyswitch to the ON position.

C. Determine if a diagnostic trouble code is present.

2. Check for a Failed Sensor Failed Result: The suspect sensor supply active code changes to
A. Connect to the electronic service tool. Sensor logged when a sensor is unplugged.

B. Turn the keyswitch to the ON position. Repair: Replace the failed sensor.

C. Disconnect a sensor on the suspect sensor supply circuit. Verify that the repair resolved the problem.

D. Monitor the electronic service tool when the sensor is discon- Result: The suspect sensor supply active code remains ac-
nected to see if the active code changes to logged. tive after all sensors on the sensor supply circuit have been
checked.
E. Connect the suspect sensor to the wiring harness
Repair: A failed wiring harness has been detected. Repair
F. Repeat steps C through E for each sensor on the suspect sensor or replace the wiring harness.
supply. Refer to Troubleshooting, Component Location for the lo-
cations of the sensors on the engine. Verify that the repair resolved the problem.

If the procedure did not correct the fault, contact the Dealer Solutions Network (DSN).

i07638423

Speed Control (Analog) - Test

This procedure covers the following diagnostic

codes:
Table 196
Diagnostic Trouble Codes for Analog Throttles

J1939 Code Code Description Comments

Accelerator Pedal Position 1 : Voltage Above The Electronic Control Module (ECM) detects one of the following
91-3
Normal conditions:

The ECM has been powered for 3 seconds.

Diagnostic code 168-4 is not active.

3509 codes are not active.

29-3 Accelerator Pedal Position 2: Voltage Above Normal
The setting for the upper diagnostic limit has been exceeded for one
second.

If equipped, the warning lamp will come on. The diagnostic code will
be logged.

(continued)

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(Table 196, contd)

Diagnostic Trouble Codes for Analog Throttles

J1939 Code Code Description Comments

Accelerator Pedal Position 1 : Voltage Below The ECM detects one of the following conditions:
91-4
Normal
The ECM has been powered for 3 seconds.

Diagnostic code 168-4 is not active.

3510 codes are not active.

29-4 Accelerator Pedal Position 2: Voltage Below Normal
The setting for the lower diagnostic limit has been exceeded for one
second.

If equipped, the warning lamp will come on. The diagnostic code will
be logged.

Follow the troubleshooting procedure in order to identify the root cause of the fault.

If a fault occurs with the primary throttle with The sensor receives +5 VDC power from the ECM.
secondary throttle is installed, the secondary throttle The sensor will produce a raw signal voltage that will
will be used until the fault is repaired. alter between low idle and high idle. The voltage is
changed into a throttle position within the range 0%
If a fault occurs with the secondary throttle, the to 100% by the ECM.
engine will use the primary throttle until the fault is
repaired. The sensor senses the speed requirement from the
throttle position. A second sensor may override this
If a functional throttle is not available, the following speed requirement from the first sensor. This
conditions will occur: override will be subject to an input from a secondary
throttle or from the SAE J1939 (CAN) data link or
• The engine will default to the limp home speed. from a PTO control.
• If the engine speed is higher than the limp home Use the electronic service tool in order to check the
speed, the engine will decelerate to the limp home input status.
speed.
Note: The identification letters for the terminals in the
• If the engine speed is lower than the limp home connectors may vary dependent on the manufacturer
speed, the engine speed will remain at the current of the throttle pedal.
speed.
Complete the procedure in the order in which the
• The engine will remain at this speed while the steps are listed.
diagnostic code remains active.

• All inputs from the faulty throttle are ignored by the

ECM until the fault is repaired.

• All inputs from the repaired throttle will be ignored

by the ECM until the keyswitch has been cycled.
The diagnostic codes above relate to an analog
sensor. Use this procedure only if the analog sensor
uses an output from a variable resistor.
The sensor is most likely to be mounted on a throttle
pedal. The sensor is attached directly to the throttle
assembly. The sensor provides an output voltage to
the ECM. The sensor output voltage will vary with the
position of the throttle. Foot operated or hand
operated throttle assemblies are available.

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Illustration 55 g06383555
Schematic of the analog throttle position sensor circuit.

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the line heater connectors
and the ECM connectors.

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 M0095947-10 337
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Table 197
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection or Result: There is a fault in a connector or the wiring.
damaged wire
A. Thoroughly inspect the terminal connections on the analog Repair: Repair any faulty connectors or replace the wir-
throttle position sensors and any interface connectors be- ing harness. Ensure that all the seals are properly in
tween the sensors and the ECM. place and ensure that the connectors are correctly
Refer to Troubleshooting, “Electrical Connector - Inspect”. coupled.

B. Perform a 30 N (6.7 lb) pull test on each of the wires that Use the electronic service tool to clear all logged diag-
are associated with the active diagnostic code in the analog nostic codes and verify that the repair eliminates the
throttle position sensor connectors and the interface connec- fault.
tors .
Result: All connectors, pins, and sockets are correctly
C. Check the harness for corrosion, abrasion, and pinch points coupled and/or inserted. The harness is free of corro-
from the analog throttle position sensors to the ECM. sion, abrasion, and pinch points.

Note: Do not disconnect the ECM connector at this stage. The Proceed to Test Step 2.
ECM can only be disconnected and reconnected 10 times be-
fore damage to the harness connector may occur.

2. Check for Active Diagnostic Codes Diagnostic codes Result: There are no active diagnostic codes for the
analog throttle position sensors.
A. Turn the keyswitch to the OFF position.
Proceed to Test Step 3.
B. Connect the electronic service tool to the diagnostic
connector. Result: One or more of the diagnostic codes listed in Ta-
ble 196 is active.
C. Turn the keyswitch to the ON position. Wait at least 10 sec-
onds for activation of the diagnostic codes. Proceed to Test Step 5.

D. Verify if any of the diagnostic codes that are listed in Table

196 are active.

E. Turn the keyswitch to the OFF position.

3. Check the Throttle Position with the Electronic Service 20 percent to 27 per- Result: The ECM is not receiving the correct signal from
Tool cent at low idle. the sensor.

A. Connect the electronic service tool to the diagnostic 80 percent to 87 per- Repair: Use the electronic service tool to verify that the
connector. cent at high idle throttle has been configured correctly before continuing
with this procedure.
B. Turn the keyswitch to the ON position. Do not start the If the fault is still present after the throttle has been con-
engine. figured correctly, replace the analog throttle position
sensor.
C. Observe the throttle position reading on the electronic serv-
ice tool. Result: The sensor is operating correctly.

D. Operate the throttle over the full range of movement. Proceed to Test Step 4.

(continued)

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(Table 197, contd)

Troubleshooting Test Steps Values Results

4. Check the Throttle Selection Status with the Electronic Throttle 1 has control Result: The throttle section switch is operating correctly.
Service Tool when status is “OFF”
. Return the engine to service.
A. Check the status of the throttle selection switch (if
equipped). Use the electronic service tool to check the status Throttle 2 has control If an intermittent fault exists, refer to Troubleshooting,
of the throttle selection switch. when status is ON. “Electrical Connector - Inspect”

Result: The wrong throttle is selected.

Repair: Switch to the other throttle. There may be a fault

with the selector switch input.

Check the connections between the throttle selection

switch and the P1 connector. Refer to Troubleshooting,
“Electrical Connector - Inspect”.

5. Check the Sensor Supply Voltage 4.84 VDC to 5.16 Result: The correct supply voltage is not reaching the
VDC sensor. The fault is in the 5 VDC supply wire or the
A. Turn the keyswitch to the OFF position. ground wire between the suspect throttle position sensor
and the P1 connector.
B. Disconnect the connector for the suspect throttle position
sensor. Repair: Repair the faulty wiring or replace the faulty
wiring.
C. Turn the keyswitch to the ON position.
Use the electronic service tool to clear all logged diag-
D. Measure the voltage between the 5 VDC terminal and the nostic codes and verify that the repair eliminates the
ground terminal on the harness connector for the sensor. fault.

Result: The supply voltage is reaching the sensor.

Proceed to Test Step 6.

6. Verify the Type of Active Diagnostic Code Diagnostic codes Result: A -3 diagnostic code is active.

A. Turn the keyswitch to the ON position. Wait at least 10 sec- Proceed to Test Step 7.
onds for activation of the diagnostic codes.
Result: A -4 diagnostic code is active.
B. Use the electronic service tool to check for active diagnostic
codes that are listed in Table 196 . Record all active diagnostic Proceed to Test Step 10.
codes.
Result: There are no active diagnostic codes for the
throttle position sensors - The fault may be intermittent.

Repair: Refer to Troubleshooting, “Electrical Connector

- Inspect”.

(continued)

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(Table 197, contd)

Troubleshooting Test Steps Values Results

7. Create a Short Circuit at the Sensor Connector Diagnostic codes Result: An -3 diagnostic code was active before the
jumper was installed. An -4 diagnostic code is active with
A. Turn the keyswitch to the OFF position. the jumper installed.

B. Disconnect the throttle position sensor with the -3 diagnos- Repair: Install a replacement analog throttle position
tic code. sensor.

C. Fabricate a jumper wire. Install the jumper wire between Use the electronic service tool to clear all logged diag-
the sensor signal terminal and the ground terminal on the har- nostic codes and verify that the repair eliminates the
ness connector for the throttle position sensor. fault.

D. Turn the keyswitch to the ON position. Result: The -3 diagnostic code remains active with the
jumper installed.
E. Access the “Active Diagnostic Codes” screen on the elec-
tronic service tool. Look for an active -4 diagnostic code for Proceed to Test Step 8.
the suspect sensor.

F. Turn the keyswitch to the OFF position.

G. Remove the jumper wire.

8. Check the Wiring Between the Throttle Position Sensor Less than 2 Ohms Result: The resistance is greater than 2 Ohms - There
and the Interface Connector (if equipped) for an Open is a fault in the wiring between the throttle position sen-
Circuit sor connector and the interface connector.

Note: This step is only applicable if an interface connector is Repair: Repair the faulty wiring or replace the faulty
installed between the throttle position sensors and the ECM. wiring.
Refer to the Electrical Schematic for the application for more
information. Proceed to Test Step 9if no interface connector is Result: All measured resistances are less than 2 Ohms.
installed.
Reconnect all connectors. Proceed to Test Step 9.
A. Turn the keyswitch to the OFF position.

B. Disconnect the connector for the suspect throttle position

sensor. Disconnect the interface connector between the throt-
tle sensor and the ECM.

C. Use a suitable multimeter to measure the resistance be-

tween the sensor signal terminal on the sensor connector and
the sensor signal terminal on the interface connector.

9. Check the Sensor Signal Wire for an Open Circuit Less than 2 Ohms Result: The resistance measurement is greater than 2
Ohms - There is an open circuit or high resistance in the
A. Turn the keyswitch to the OFF position. sensor signal wire.

B. Disconnect the suspect throttle position sensor. Disconnect Repair: Repair the faulty wiring or replace the faulty
the P1 connector from the ECM. Thoroughly inspect the P1/J1 wiring.
connectors for corrosion or damage. Refer to Troubleshooting,
Electrical Connectors - Inspect. Use the electronic service tool to clear all logged diag-
nostic codes and verify that the repair eliminates the
C. Measure the resistance between the sensor signal terminal fault.
on the harness connector and the appropriate sensor signal
terminal on the P1 connector. Result: The resistance measurement is less than 2
Ohms.

Contact the Dealer Solutions Network (DSN).

(continued)

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(Table 197, contd)

Troubleshooting Test Steps Values Results

10. Create an Open Circuit at the Sensor Connector Diagnostic codes Result: An -4 diagnostic code was active before discon-
necting the sensor. An -3 diagnostic code is active with
A. Turn the keyswitch to the OFF position. the sensor disconnected.

B. Disconnect the throttle position sensor with the -4 diagnos- Repair: Install a replacement analog throttle position
tic code. sensor.

C. Turn the keyswitch to the ON position. Wait for at least 10 Use the electronic service tool to clear all logged diag-
seconds for activation of the diagnostic codes. nostic codes and verify that the repair eliminates the
fault.
D. Use the electronic service tool to check the “Active Diag-
nostic Codes” screen on the electronic service tool. Check for Result: The -4 diagnostic code is still active with the
an -3 diagnostic code. sensor disconnected.

E. Turn the keyswitch to the OFF position. Proceed to Test Step 11.

11. Check the Wiring Between the Throttle Position Sen- Greater than 1 k Result: At least one of the resistance measurements is
sor and the Interface Connector (if equipped) for a Short Ohm less than 1 k Ohm. There is a fault in the wiring between
Circuit the throttle position sensor connector and the interface
connector.
Note: This step is only applicable if an interface connector is
installed between the throttle position sensors and the ECM. Repair: Repair the faulty wiring or replace the faulty
Refer to the Electrical Schematic for the application for more wiring.
information. Proceed to Test Step 12 if no interface connector
is installed.
Result: All measured resistances are greater than 1 k
A. Turn the keyswitch to the OFF position. Ohm.

B. Disconnect the connector for the suspect throttle position Reconnect all connectors. Proceed to Test Step 12.
sensor. Disconnect the interface connector between the throt-
tle position sensors and the ECM.

C. Use a suitable multimeter to measure the resistance be-

tween the suspect sensor signal terminal on the interface con-
nector and all other terminals on the interface connector.

12. Check the Sensor Signal Wire for a Short Circuit Greater than 1k Ohm Result: At least one of the resistance measurements is
less than 1k Ohm - There is a short in the wiring
A. Turn the keyswitch to the OFF position. harness.

B. Disconnect the suspect throttle position sensor. Disconnect Repair: Repair the faulty wiring or replace the faulty
the P1 connector from the ECM. wiring.

C. Measure the resistance between the suspect sensor signal Result: All resistance measurements are greater than
terminal and all other terminals on the P1 connector. 1k Ohm.

Contact the Dealer Solutions Network (DSN).

i08250969

Speed Control (PWM) - Test

Use this procedure if the digital throttle position

sensor is suspected of incorrect operation. This
procedure also covers the following diagnostic
codes:

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 M0095947-10 341
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Table 198
Diagnostic Trouble Codes for the Digital Throttles

J1939 Code Code Description Comments

The Electronic Control Module (ECM) detects the following conditions:

The ECM has been powered for 3 seconds.

Diagnostic code 168-4 is not active.

Accelerator Pedal Position 2 : Voltage Above
29-3
Normal
The setting for the upper diagnostic limit has been exceeded for one
second.

If equipped, the warning lamp will come on. The diagnostic code will be
logged.

The ECM detects the following conditions:

The ECM has been powered for 3 seconds.

Diagnostic code 168-4 is not active.

Accelerator Pedal Position 2 : Voltage Below
29-4
Normal
The setting for the lower diagnostic limit has been exceeded for one
second.

If equipped, the warning lamp will come on. The diagnostic code will be
logged.

The ECM detects the following conditions:

The signal frequency from the digital throttle position sensor is equal to
0% or 100% for more than 2 seconds.

The ECM has been powered for at least 3 seconds.

Accelerator Pedal Position 2 : Abnormal Frequency,
29-8
Pulse Width, or Period
Diagnostic codes 29-3 and 29-4 are not active.

The ECM sets the Throttle Position to “0%” .

If equipped, the warning lamp will come on. The diagnostic code will be
logged if the engine is running. The diagnostic code will not be logged if
the engine is cranking.

The Electronic Control Module (ECM) detects the following conditions:

The ECM has been powered for 3 seconds.

Diagnostic code 168-4 is not active.

Accelerator Pedal Position 1 : Voltage Above
91-3
Normal
The setting for the upper diagnostic limit has been exceeded for one
second.

If equipped, the warning lamp will come on. The diagnostic code will be
logged.

(continued)

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 342 M0095947-10
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(Table 198, contd)

Diagnostic Trouble Codes for the Digital Throttles

J1939 Code Code Description Comments

The ECM detects the following conditions:

The ECM has been powered for 3 seconds.

Diagnostic code 168-4 is not active.

Accelerator Pedal Position 1 : Voltage Below
91-4
Normal
The setting for the lower diagnostic limit has been exceeded for one
second.

If equipped, the warning lamp will come on. The diagnostic code will be
logged.

The ECM detects the following conditions:

The signal frequency from the digital throttle position sensor is equal to
0% or 100% for more than 2 seconds.

Accelerator Pedal Position 1 : Abnormal Frequency, The ECM has been powered for at least 3 seconds.
91-8
Pulse Width, or Period
Diagnostic codes 91-3 and 91-4 are not active.
The ECM sets the Throttle Position to “0%” .
If equipped, the warning lamp will come on. The diagnostic code will be
logged if the engine is running. The diagnostic code will not be logged if
the engine is cranking.

Follow the troubleshooting procedure to identify the root cause of the fault.

If a fault occurs with the primary throttle, the engine The digital throttle position sensor is used to provide
will use the secondary throttle until the fault is a digital throttle position signal to the ECM. The
repaired. sensor output is a constant frequency signal with a
pulse width that varies with the throttle position. This
If a fault occurs with the secondary throttle, the output signal is referred to as either a duty cycle or a
engine will use the primary throttle until the fault is pulse width modulated signal (PWM). This output
repaired. signal is expressed as a percentage between 0 and
100 percent.
If a functional throttle is not available, the following
conditions will occur: The digital throttle position sensor is most likely to be
attached directly to the throttle assembly. The digital
• The engine will default to the limp home speed. throttle position sensor requires no adjustment.
• If the engine speed is higher than the limp home The duty cycle at low idle and the duty cycle at high
speed, the engine will decelerate to the limp home idle can vary depending on the application. The
speed. percent of duty cycle is translated in the ECM into a
throttle position of 3 to 100 percent.
• If the engine speed is lower than the limp home
speed, the engine speed will remain at the current The digital throttle position sensors are powered by
speed. +5 VDC from the ECM. The supply voltage is from
J1: to the digital throttle position sensor connector.
• The engine will remain at this speed while the
diagnostic code remains active. If the application is using the ECM dedicated PTO
functions, the digital throttle position sensor will be
• All inputs from the faulty throttle are ignored by the ignored while the engine is in PTO mode.
ECM until the fault is repaired.
The ECM is in PTO mode if the PTO ON/OFF Switch
is ON. This status can be checked with the electronic
• All inputs from the repaired throttle will be ignored service tool. Refer to Troubleshooting, “Power Take-
by the ECM until the keyswitch has been cycled. Off - Test” for testing if the PTO is being used.
Digital Throttle Position Sensor Note: The identification letters for the terminals in the
connectors may vary dependent on the manufacturer
of the throttle pedal.

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 M0095947-10 343
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During the following procedure, refer to the electrical

schematic for the application.
Complete the procedure in the order in which the
steps are listed.
Table 199
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection or Result: There is a fault in a connector or the wiring.
damaged wire
A. Thoroughly inspect the terminal connections on the P1/J1 Repair: Repair any faulty connectors or replace the wir-
and P2/J2 ECM connectors and the PWM throttle position ing harness. Ensure that all the seals are properly in
sensors. place and ensure that the connectors are correctly
Refer to Troubleshooting, “Electrical Connector - Inspect”. coupled.

B. Perform a 30 N (6.7 lb) pull test on each of the wires in the Use the electronic service tool to clear all logged diag-
ECM connector and the PWM throttle position sensor nostic codes and verify that the repair eliminates the
connector. fault.

C. Check the harness for corrosion, abrasion, and pinch points Result: All connectors, pins, and sockets are correctly
from the PWM throttle position sensor to the ECM. coupled and/or inserted. The harness is free of corro-
sion, abrasion, and pinch points.

Proceed to Test Step 2.

2. Check for Active Diagnostic Codes Diagnostic codes Result: At least one of the diagnostic codes listed in Ta-
ble 198 is active.
A. Turn the keyswitch to the OFF position.
Proceed to Test Step 4.
B. Connect the electronic service tool to the diagnostic
connector. Result: None of the preceding diagnostic codes are ac-
tive or recently logged - There may be an intermittent
C. Turn the keyswitch to the ON position. Wait at least 10 sec- fault.
onds for activation of the diagnostic codes.
Repair: Refer to Troubleshooting, “Electrical Connector
D. Verify if any of the diagnostic codes that are listed in Table - Inspect” to identify intermittent faults.
198 are active. If the fault is still present, proceed to Test Step 3.
Note: When the ECM calibrates new duty cycle values for the
low and the high idle throttle position, the ECM assumes the
initial lower position for the duty cycle at low idle and the initial
upper position for the duty cycle at high idle. The initial lower
position and the initial upper position can be obtained by ac-
cessing the following screens on the electronic service tool:
· Service
· Throttle Configuration
· “Throttle# 1”
As a result, the throttle position status may reach 100 percent
well before the throttle pedal is fully depressed. This situation
is normal. Cycle the throttle to the high idle position several
times for the ECM to adjust the calibration automatically. Dur-
ing normal operation, more movement of the throttle can be
required for the throttle position status to increase above 3
percent. The status may reach the 100 percent value prior to
the limit of the high idle position. This process is done to en-
sure that the throttle reaches these two critical points for en-
gine operation.

E. Turn the keyswitch to the OFF position.

(continued)

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 344 M0095947-10
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(Table 199, contd)

Troubleshooting Test Steps Values Results

3. Check the Duty Cycle of the Digital Throttle Position Duty cycle above Result: OK - The digital throttle position sensor is oper-
Sensor lower diagnostic limit ating correctly.
at low idle
A. Access the following screens on the electronic service tool Return the engine to service.
to check the upper and the lower diagnostic limit of the throttle Duty cycle below
position sensors: upper diagnostic limit Result: Not OK - The digital throttle position sensor cir-
· “Service” at high idle cuit is not operating correctly.
· “Throttle Configuration”
· “Throttle# 1” Proceed to Test Step 4.

B. Make a note of the lower diagnostic limit and the upper di-
agnostic limit.

C. Verify that the keyswitch is in the ON position.

D. Access the following screens on the electronic service tool

to monitor the duty cycle of the throttle position:
· “Status”
· “Throttles”

E. Monitor the duty cycle of the throttle at the “low idle” posi-
tion and the “high idle” position.

4. Check the Supply Voltage at the Digital Throttle Posi- 4.84 VDC to 5.16 Result: The sensor supply voltage is not within the ex-
tion Sensor VDC pected range. The fault is in the sensor supply wiring or
the ground wiring between the sensor and the ECM.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty
B. Install a breakout “T” with three terminals at the suspect wiring.
digital throttle position sensor connector.
Use the electronic service tool to clear all logged diag-
C. Turn the keyswitch to the ON position. nostic codes and verify that the repair eliminates the
fault.
D. Measure the voltage between the +5 VDC terminal and the
sensor return terminal. Result: The sensor supply voltage is within the expected
range.

Proceed to Test Step 5.

(continued)

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 M0095947-10 345
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(Table 199, contd)

Troubleshooting Test Steps Values Results

5. Check the Duty Cycle of the Throttle Position Sensor at Duty cycle above Result: Not OK.
the Sensor lower diagnostic limit
at low idle Repair: Replace the suspect digital throttle position
Note: Performing certain steps within this procedure requires sensor.
the use of a multimeter that can measure a PWM duty cycle. Duty cycle below
upper diagnostic limit Use the electronic service tool to clear all logged diag-
A. Access the following screens on the electronic service tool at high idle nostic codes and verify that the repair eliminates the
to check the upper and the lower diagnostic limit of the sus- fault.
pect throttle position sensors:
· “Service” Result: OK.
· “Throttle Configuration”
· “Throttle# 1” Proceed to Test Step 6.

B. Make a note of the lower diagnostic limit and the upper di-
agnostic limit.

C. Turn the keyswitch to the OFF position.

D. Remove the signal wire for the suspect digital throttle posi-
tion sensor from the connector. Refer to the Electrical Sche-
matic for the application.

E. Install a breakout “T” with three terminals at the digital throt-

tle position sensor connector.

F. Connect the multimeter probes to the sensor signal terminal

and the sensor ground terminal of the breakout T.

G. Turn the keyswitch to the ON position.

H. While the duty cycle is being monitored on the multimeter,

operate the throttle through the full range of movement.

6. Bypass the Signal Wire Duty cycle above Result: OK - The throttle operates correctly with the by-
lower diagnostic limit pass installed. The fault is in the sensor signal wiring.
at low idle
A. Turn the keyswitch to the OFF position. Repair: Repair the faulty wiring or replace the faulty
Duty cycle below wiring.
B. Disconnect the suspect digital throttle position sensor con- upper diagnostic limit
nector. Disconnect the P1 connector from the ECM. at high idle Use the electronic service tool to clear all logged diag-
nostic codes and verify that the repair eliminates the
C. Remove the sensor signal wire from the connector for the fault.
suspect digital throttle position sensor. Remove the applicable
signal wire from P1. Result: Not OK

D. Install the jumper wire between P1 and the signal terminal Repair: Recheck the wiring, the ECM connectors, and
on the suspect throttle sensor connector. the digital throttle position sensor connector.
If no faults are found, contact the Dealer Solutions Net-
E. Access the following screens on the electronic service tool work (DSN).
to check the upper and the lower diagnostic limit of the throttle
position sensor:
· “Service”
· “Throttle Configuration”
· “Throttle# 1”

F. Make a note of the lower diagnostic limit and the upper diag-
nostic limit.

(continued)

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 346 M0095947-10
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(Table 199, contd)

Troubleshooting Test Steps Values Results
G. Turn the keyswitch to the ON position.

H. Check the duty cycle of the position sensor on the elec-

tronic service tool while the digital throttle is being moved over
the full range.

i07988061

Speed/Timing - Test

Use this procedure to troubleshoot the electrical

system if a problem is suspected with the primary
engine speed/timing sensor. Also use this procedure
if a problem is suspected with the secondary engine
speed/timing sensor. Use this procedure to
troubleshoot the electrical system if a diagnostic code
in Table 200 is active or easily repeated.
Table 200
Diagnostic Trouble Codes for the Speed/Timing Sensors

J1939 Code Code Description Comments

190-8 Engine Speed Sensor : Abnor- The code is logged. The Electronic Control Module (ECM) can default to the
mal Frequency, Pulse Width, or secondary engine speed/timing sensor. The default will occur if a valid signal
Period is not received from the primary engine speed/timing sensor. The engine will
shut down only if the signals from the primary engine speed/timing sensor and
the secondary engine speed/timing sensor are abnormal.

723-8 Engine Speed Sensor #2 : Ab- The code is logged. If a valid signal is not received from the secondary engine
normal Frequency, Pulse Width, speed/timing sensor, the ECM will default to the primary engine speed/timing
or Period sensor. The engine will shut down only if the signals from the primary engine
speed/timing sensor and the secondary engine speed/timing sensor are
abnormal.
637–11 Engine Timing Sensor : Other The Electronic Control Module (ECM) detects the following conditions:
Failure Mode
The outputs from the primary speed/timing sensor and the secondary speed/
timing sensor differ by more than 8 degrees of crankshaft rotation.

The engine has been running for more than 5 seconds.

The warning light will come on. This code will not be logged.

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 M0095947-10 347
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Illustration 56 g06498452

Table 201
Troubleshooting Test Steps Values Results

1. Check the Engine Speed/Timing Circuit Speed/Timing Result: The engine started.
Circuit
A. Connect the electronic service tool to the service tool connector. Proceed to Test Step 2.
Refer to Troubleshooting, “Electronic Service Tools”.
Result: The engine did not start.
B. Turn the keyswitch to ON.
Proceed to Test Step 3.

C. Start the engine and run the engine.

Note: The problem may occur when the engine is at any operating
temperature. However, the problem is more likely to occur when the
engine is at the normal operating temperature.

2. Check for Codes Codes Result: Diagnostic code 637–11 is active.

A. While the engine is running, monitor the electronic service tool for Proceed to Test Step 3.
diagnostic codes. Also monitor the “Engine Starting” screen for an
engine speed/timing that is “Not Detected” . Result: Diagnostic code 190–8 or 723–8 is active or
there is a timing pattern that is “Not Detected” .
B. Wait at least 30 seconds for activation of the diagnostic codes.
Look for these codes on the electronic service tool: Proceed to Test Step 4.

• 190-8 Result: There is not an active diagnostic code and there

• 723-8 is not a timing pattern that is “Not Detected” .
•637–11
Repair: Download the “Product Status Report” (PSR)
from the engine ECM. Troubleshoot any diagnostic codes
that may be present.

Return the unit to service.

(continued)

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 348 M0095947-10
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(Table 201, contd)

Troubleshooting Test Steps Values Results

3. Inspect the Sensors Faulty sensor Result: A 637-11 diagnostic code is no longer active.

A. Ensure that the speed/timing sensors are correctly seated in the Use the electronic service tool to clear all logged diagnos-
flywheel housing and the cylinder block and that the retaining bolts tic codes. Return the engine to service.
are tightened to a torque of 22 N·m (16 lb ft). Ensure that the speed/
timing sensors are not damaged. Result: A 637-11 diagnostic code is still active.

Replace any damaged sensors. Refer to Disassembly and Assem- Repair: If the engine has been reworked before the ac-
bly, “Crankshaft Position Sensor - Remove and Install” or refer to tive 637-11 diagnostic code occurred, ensure that the fly-
Disassembly and Assembly, “Camshaft Position Sensor - Remove wheel and the camshaft gear have been aligned
and Install”. correctly.

B. Turn the keyswitch to the ON position. If the engine will run, then If the fault is still present, contact the Dealer Solutions
run the engine. Network (DSN).

C. Use the electronic service tool to check if the 637-11 diagnostic

code is still active.

4. Check the Battery Voltage Battery Result: The battery voltage is OK.
Voltage
A. Monitor the “Engine Starting” screen in the electronic service tool. Proceed to Test Step 5.

B. Monitor the “Battery Voltage” . Crank the engine for 5 seconds. Result: The battery voltage is not OK.

Repair: Refer to Troubleshooting, “Engine Cranks but

Does Not Start”.

5. Check the Engine Speed and the Engine Speed/Timing Status Speed/Timing Result: The sensors show an acceptable cranking
Status speed. The timing pattern shows “Detected” .
A. Monitor the “Engine Starting” screen in the electronic service tool.
Repair: Refer to Troubleshooting, “Engine Cranks but
B. Crank the engine for 5 seconds. While the engine is cranking, ver- Does Not Start”.
ify that the sensors show an acceptable cranking speed.
Result: A sensor does not show an acceptable cranking
C. While the engine is cranking, check the status of the engine speed and/or the timing pattern shows “Not Detected” .
speed/timing.
Proceed to Test Step 6.

6. Check the Speed/Timing Sensor Speed/Timing Result: The sensor and the sensor assembly mounting
Sensor are OK. Do not reconnect the harness connector.
A. Turn the keyswitch to OFF.
Proceed to Test Step 7.
B. Visually inspect the sensor and the sensor assembly without re-
moving the sensor assembly from the engine. Flanges must be flush Result: The sensor and/or the sensor assembly has a
against the surface of the timing gear housing and the flywheel hous- mechanical problem or the harness has debris and/or
ing to ensure proper operation. corrosion.

C. Disconnect the harness from the speed/timing sensors. Check Repair: Repair the sensor and/or the sensor assembly or
the harness for debris and for corrosion. replace the sensor and/or the sensor assembly. Replace
the sensor and the sensor harness connector if there was
F. Perform a 45 N (10 lb) pull test on the harness wiring. debris and/or corrosion.

Verify that the problem is resolved.

(continued)

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 M0095947-10 349
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(Table 201, contd)

Troubleshooting Test Steps Values Results

7. Use a Multimeter to Check the Harness Wiring at the Sensor Check Wiring Result: The voltage was OK for all the measurements.
Connector Harness
Repair: Replace the affected speed/timing sensor.
A. Disconnect the affected speed/timing sensor from the wiring
harness. Result: The voltage was not OK for at least one of the
measurements.
B. Turn the keyswitch to ON.
Proceed to Test Step 8.
C. Perform substeps D-E for the affected sensor.

D. Measure the voltage between terminal 3 (5V SUPPLY) and termi-

nal 2 (RETURN). The voltage should be 5V +/-.2V.

E. Measure the voltage between terminal 1 (SIGNAL) and terminal 2

(RETURN). The voltage should be 4.8V +/- 0.3V.

8. Use a Multimeter to Check the Harness Wiring at the Engine Check Wiring Result: The voltage was OK for all the measurements.
Interface Connector Harness The fault is in the engine wiring harness.

A. Disconnect the engine interface connector. Repair: Repair or replace the engine wiring harness.

B. Turn the keyswitch to ON. Result: The voltage was not OK for at least one of the
measurements. The fault is in the wiring between the en-
C. Perform substeps D-E for the affected sensor. gine interface connector and the ECM.

D. Measure the voltage between the 5V supply terminal and the sen- Repair the faulty wiring or replace the faulty wiring.
sor return terminal on the engine interface connector (ECM side).
The voltage should be 5V +/-.2V.

E. Measure the voltage between the sensor signal terminal and the
sensor return terminal on the engine interface connector (ECM side).
The voltage should be 4.8V +/- 0.3V.

If the procedure did not correct the issue, contact the

Dealer Solutions Network (DSN).

i07618451

Switch Circuits - Test

(Engine Oil Pressure Switch)

Use this procedure to diagnose electronic faults in

the oil pressure switch circuit.
This procedure covers the following diagnostic code:

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 350 M0095947-10
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Table 202
Diagnostic Trouble Codes for the Oil Pressure Switch

J1939 Code Description Notes

100-2 Engine Oil Pressure : Erratic, Intermittent, or Incorrect When the keyswitch is in the ON position (engine not run-
ning), the oil pressure switch circuit should be closed.

This diagnostic code will be active when the Electronic Con-

trol Module (ECM) detects the following conditions:
The engine is not running.
The circuit for the oil pressure switch is open.
The warning lamp will come on.

The engine is equipped with an oil pressure switch.

While the engine is running and oil pressure is
detected, the switch will be open. When no oil
pressure is detected, the switch will be closed.
Table 203
Oil Pressure Switch States and Diagnostics Summary

Oil Pressure Switch Active Diagnostic

Engine Condition
State Code
Not running Closed Normal condition
(no oil pressure
detected)

Running Open Normal condition (oil

pressure detected)

Not running Open 100-2

Running Closed 100-1

Note: If a 100-1 diagnostic code is active, refer to

Troubleshooting, “Oil Pressure Is Low” before
returning to this procedure.

Illustration 57 g06380128
Schematic diagram for the oil pressure switch circuit

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the oil pressure switch
connector and the ECM connectors.

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 M0095947-10 351
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Table 204
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found.
or connector
A. Thoroughly inspect the connector for the oil pressure Repair: Repair the damaged wire or the damaged connector.
switch and the engine interface connector. Refer to Trouble- Use the electronic service tool to clear all logged diagnostic co-
shooting, “Electrical Connectors - Inspect”. des. Verify that the repair eliminates the fault.

Result: All connectors, pins, and sockets are correctly con-

B. Perform a 30 N (6.7 lb) pull test on each of the wires that nected and/or inserted and the harness is free of corrosion, of
are associated with the oil pressure switch in the oil pressure abrasion or of pinch points.
switch connector and the engine interface connector.
Proceed to Test Step 2.
C. Check the harness for abrasions and for pinch points from
the oil pressure switch back to the ECM.

Note: Do not disconnect the ECM connector at this stage.

The ECM can only be disconnected and reconnected 10
times before damage to the harness connector may occur.

2. Check for Active or Recently Logged Diagnostic Diagnostic Result: A 100-1 diagnostic code is recently logged.
Codes codes This diagnostic code indicates that the oil pressure is low, but
can also be caused by a short circuit condition in the oil pres-
A. Turn the keyswitch to the OFF position. sure switch circuit.

B. Connect the electronic service tool to the diagnostic Repair: Check for engine oil pressure problems before return-
connector. ing to this procedure. refer to Troubleshooting, “Oil Pressure Is
Low”.
C. Turn the keyswitch to the ON position. Do not start the If the fault is still present, proceed to Test Step 3.
engine.
Result: A 100-2 diagnostic code is active.
D. Check for any active or recently logged diagnostic codes.
Wait at least 30 seconds for activation of the diagnostic Proceed to Test Step 6.
codes.
Result: A 100-2 diagnostic code is not active. A 100-1 diag-
nostic code is not recently logged.
An intermittent 100-2 diagnostic code can be caused by turn-
ing the keyswitch to the ON position after the engine has re-
cently been stopped or an intermittent fault may exist.

Repair: Refer to Troubleshooting, “Electrical Connectors - In-

spect” to identify intermittent faults.

3. Create an Open Circuit at the Switch Connector Diagnostic Result: A 100-2 diagnostic code is active with the switch
codes disconnected.
A. Turn the keyswitch to the OFF position.
Repair: Replace the oil pressure switch. Refer to Disassembly
B. Disconnect the harness connector for the oil pressure and Assembly, “Engine Oil Pressure Switch - Remove and
switch. Install”.
Use the electronic service tool to clear all logged diagnostic co-
C. Turn the keyswitch to the ON position. Do not start the des and verify that the repair eliminates the fault.
engine.
Result: A 100-2 diagnostic code is not active with the oil pres-
D. Use the electronic service tool to check for an active 100-2 sure switch disconnected.
diagnostic code. Wait at least 30 seconds for activation of the
diagnostic code. Reconnect the harness connector for the oil pressure switch
and proceed to Test Step 4.

(continued)

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 352 M0095947-10
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(Table 204, contd)

Troubleshooting Test Steps Values Results

4. Create an Open Circuit at the Engine Interface Diagnostic Result: A 100-2 diagnostic code is active with the engine inter-
Connector codes face connector disconnected.
The fault is in the wiring between the engine interface connec-
A. Turn the keyswitch to the OFF position. tor and the oil pressure switch.

B. Disconnect the engine interface connector. Repair: Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic co-
C. Turn the keyswitch to the ON position. Do not start the en- des and verify that the repair eliminates the fault.
gine. Wait at least 30 seconds for activation of the diagnostic
codes. Result: A 100-2 diagnostic code is not active with the engine
interface connector disconnected.
D. Use the electronic service tool to check for an active 100-2
diagnostic code. Reconnect the engine interface connector. Proceed to Test
Step 5.
Note: Diagnostic codes for all the engine sensors will be ac-
tive with the engine interface connector disconnected. Ignore
all other codes and only look for a 100-2 diagnostic code.

E. Turn the keyswitch to the OFF position.

5. Check the Oil Pressure Switch Signal Wire for a Short Greater than 1k Result: The measured resistance is less than 1k Ohm.
to Ground Ohm There is a short to ground in the wiring between the engine in-
terface connector and the P2 connector.
A. Disconnect the P2 connector from the ECM. Thoroughly
inspect the P2/J2 connector for damage or corrosion. Refer Repair: Repair the faulty wiring or replace the faulty wiring.
to Troubleshooting, Electrical Connectors - Inspect for more Use the electronic service tool to clear all logged diagnostic co-
information. des and verify that the repair eliminates the fault.

B. Disconnect the engine interface connector. Result: The measured resistance is greater than 1k Ohm.

C. Use a suitable multimeter to measure the resistance be- Contact the Dealer Solution Network (DSN).
tween terminal 22 on the engine interface connector and a
suitable ground.

6. Create a Short at the Switch Connector Diagnostic Result: A 100-2 diagnostic code is not active with the jumper
codes installed.
A. Turn the keyswitch to the OFF position.
Repair: Replace the oil pressure switch. Refer to Disassembly
B. Disconnect the harness connector for the oil pressure and Assembly, “Engine Oil Pressure Switch - Remove and
switch. Install”.
Use the electronic service tool to clear all logged diagnostic co-
C. Fabricate a jumper wire and install the jumper wire be- des and verify that the repair eliminates the fault.
tween the terminal 1 and terminal 2 on the harness connector
for the oil pressure switch. Result: A 100-2 diagnostic code is active with the jumper
installed.
D. Turn the keyswitch to the ON position. Do not start the
engine. Proceed to Test Step 7.

E. Use the electronic service tool to check for an active 100-2

diagnostic code. Wait at least 30 seconds for activation of the
diagnostic code.

F. Turn the keyswitch to the OFF position.

G. Remove the jumper wire.

(continued)

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(Table 204, contd)

Troubleshooting Test Steps Values Results

7. Create a Short at the Engine Interface Connector Diagnostic Result: A 100-2 diagnostic code is not active with the jumper
codes installed.
A. Turn the keyswitch to the OFF position. There is an open circuit in the wiring between the oil pressure
switch and the engine interface connector.
B. Disconnect the engine interface connector.
Repair: Repair the faulty wiring or replace the faulty wiring.
C. Fabricate a jumper wire and install the jumper wire be- Use the electronic service tool to clear all logged diagnostic co-
tween terminal 17 and terminal 22 on the engine interface des and verify that the repair eliminates the fault.
connector (ECM side).
Result: A 100-2 diagnostic code is active with the jumper
D. Turn the keyswitch to the ON position. Do not attempt to installed.
start the engine. Wait at least 30 seconds for activation of the
diagnostic codes. Reconnect the engine interface connector. Proceed to Test
Step 8.
E. Use the electronic service tool to check for an active 100-2
diagnostic code.
Note: Diagnostic codes for all the engine sensors will be ac-
tive with the engine interface connector disconnected. Ignore
all other codes and only look for a 100-2 diagnostic code.

8. Check the Wiring Between the Engine Interface Con- Less than 2 Result: At least one of the resistance measurements is great-
nector and the ECM for an Open Circuit Ohms er than 2 Ohms.
There is an open circuit in the wiring between the engine inter-
A. Disconnect the P2 connector from the ECM. Thoroughly face connector and the P2 connector.
inspect the P2/J2 connector for damage or corrosion. Refer
to Troubleshooting, Electrical Connectors - Inspect for more Repair: Repair the faulty wiring or replace the faulty wiring.
information. Use the electronic service tool to clear all logged diagnostic co-
des and verify that the repair eliminates the fault.
B. Disconnect the engine interface connector.
Result: Both the resistance measurements are less than 2
C. Use a suitable multimeter to measure the resistance be- Ohms.
tween terminal 17 on the engine interface connector and
P2:45. Contact the DSN.

D. Use a suitable multimeter to measure the resistance be-

tween terminal 22 on the engine interface connector and
P2:44.

i07705003

Switch Circuits - Test

(Air Filter Restriction Switch)

Use the following procedure to troubleshoot a

problem with the air filter restriction switch circuit.
The procedure that follows also covers the diagnostic
codes that are listed in Table 205 .
Table 205
Diagnostic Trouble Codes for the Air Filter Restriction Switch

J1939 Code Code Description Comments

(continued)

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(Table 205, contd)

107-3 Air Filter Differential Pressure Switch voltage above This code indicates a fault in the circuit for the air filter restriction switch.
normal
The Electronic Control Module (ECM) detects the following conditions:
The air filter restriction switch circuit is open for at least 1 second.
The engine is not running.

Monitoring of air filter restriction when the engine is running will be dis-
abled whilst this code is active.
107-4 Air Filter Differential Pressure Switch voltage below This code indicates a fault in the circuit for the air filter restriction switch.
normal
The Electronic Control Module (ECM) detects the following conditions:
The air filter restriction switch circuit is grounded for at least 1 second.
The engine is not running.

Monitoring of air filter restriction when the engine is running will be dis-
abled whilst this code is active.

The engine is equipped with an air filter restriction Note: A 107-15 or a 107-16 diagnostic code
switch. The type of switch that is installed can be a indicates that the air inlet is restricted. Refer to
“Normally Open” switch or a “Normally Closed” Troubleshooting, “Inlet Air Is Restricted”.
switch.
During the following procedure, refer to the electrical
Use the electronic service tool to check the schematic for the application.
configuration parameters to check the type of air filter
restriction switch that is installed. Complete the procedure in the order in which the
steps are listed.
Table 206 and Table207 contain the normal engine
conditions and switch states for the air filter
restrictions switch.
Table 206
Diagnostic Summary for a “ Normally Open”” Air Filter Restric-
tion Switch
Active Diagnostic
Engine Condition Switch State
Code
Not running (key on) Open Normal condition

Running Open Normal Condition

(no air filter restric-
tion detected)

Not running (key on) Closed 107-4

Running Closed 107-15 or 107-16

(air filter restriction
detected)

Table 207
Diagnostic Summary for a “ Normally Closed”” Air Filter Re-
striction Switch
Active Diagnostic
Engine Condition Switch State
Code
Not running (key on) Closed Normal condition

Running Closed Normal Condition

(no air filter restric-
tion detected)

Not running (key on) Open 107-3

Running Open 107-15 or 107-16

(air filter restriction
detected)

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 M0095947-10 355
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Table 208
Troubleshooting Test Steps Values Results

1. Check the “ Air Filter Restriction Switch Configuration”” Air Filter Restriction Results : The switch is configured to “Normally Open” .
Switch Configuration
A. Turn the keyswitch to ON. Proceed to Test Step 2.

B. Connect the electronic service tool to the diagnostic Results : The switch is configured to “Normally Closed” .
connector.
Proceed to Test Step 3.
C. Under “Configuration Parameters” , check the “Air Filter
Restriction Switch Configuration” .

Note: If the type of switch cannot be identified using the elec-

tronic service tool, contact the Dealer Solutions Network
(DSN) for the information.

2. Check the Air Filter Restriction Switch Diagnostic codes Results : There is not an active 107-3 diagnostic code. A
failed air filter restriction switch has been detected.
A. Turn the keyswitch to OFF.
Repair : Replace the air filter restriction switch.
B. Disconnect the air filter restriction switch from the wiring
harness connector. Verify that the repairs eliminated the issue. Return the
machine to service.
C. Turn the keyswitch to ON.
Results : There is an active 107-3 diagnostic code. A
D. Monitor the electronic service tool for active fault codes. short circuit in the wiring harness has been detected.

Repair : Repair or replace the wiring harness.

Verify that the repair has eliminated the issue.

If the fault is still present, contact the Dealer Solutions

Network (DSN).

3. Check the Air Filter Restriction Switch Diagnostic codes Results : There is not an active 107-3 diagnostic code. A
failed air filter restriction switch has been detected.
A. Turn the keyswitch to OFF.
Repair : Replace the air filter restriction switch.
B. Disconnect the air filter restriction switch from the wiring
harness connector. Verify that the repairs eliminated the issue. Return the
machine to service.
C. Install a jumper wire in the wiring harness connector be-
tween the signal and ground terminals. Results : There is an active 107-3 diagnostic code. An
open circuit in the wiring harness has been detected.
D. Turn the keyswitch to ON.
Repair : Repair or replace the wiring harness.
E. Monitor the electronic service tool for active fault codes.
Verify that the repair has eliminated the issue.

If the fault is still present, contact the Dealer Solutions

Network (DSN).

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i07708745

Switch Circuits - Test

(Multiposition Throttle Switch)

This procedure covers the following diagnostic

codes:
Table 209
Diagnostic Trouble Codes for Throttle Switch

J1939 Code Code Description Comments

Accelerator Pedal Position #2 : Erratic, Intermit- The Electronic Control Module (ECM) detects the following condition:
29-2
tent, or Incorrect
There is an invalid combination of positions for the multi-position
switch.
Accelerator Pedal Position #1 : Erratic, Intermit-
91-2
tent, or Incorrect If equipped, the warning light will come on. The ECM will log the diag-
nostic code.
Follow the troubleshooting procedure to identify the root cause of the fault.

If the application is equipped with two throttles, the The throttle switch is typically connected to the four
engine will use the second throttle until the fault is throttle inputs of the ECM. Each position generates a
repaired. specific ON/OFF pattern on the throttle inputs. A
diagnostic code is generated if a pattern that does
If a second throttle is not installed or if the second not correspond with any of the switch positions is
throttle has a fault, the following conditions will occur: detected.
• The engine will default to the limp home speed. Once a diagnostic code is generated, the ECM
ignores the throttle input signals. The desired engine
• If the engine speed is higher than the limp home speed is set to low idle if no alternative throttle is
speed, the engine will decelerate to the limp home detected.
speed.
Voltage at the throttle inputs to the ECM should be
• If the engine speed is lower than the limp home 13.8 ± 0.5 VDC when the throttle inputs are open.
speed, the engine speed will remain at the current The voltage should be less than 0.5 VDC when the
speed. throttle inputs are closed.

• The engine will remain at this speed while the During the following procedure, refer to the electrical
diagnostic code remains active. schematic for the application.
Complete the procedure in the order in which the
• All inputs from the faulty throttle are ignored by the steps are listed.
ECM until the fault is repaired.

• All inputs from the repaired throttle will be ignored

by the ECM until the keyswitch has been cycled.
Check that the software configuration in the ECM is
correct for a multi-position throttle.
If the engine has an analog throttle with an Idle
Validation Switch (IVS), then refer to
Troubleshooting, “Idle Validation - Test”.
The throttle switch provides the operator with the
ability to select the desired engine speed. The throttle
switch configuration may be selected between 0 to 4
switches. A multi-position rotary switch may be used.

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 M0095947-10 357
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Table 210
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection or Result: There is a fault in a connector or the wiring.
damaged wire
A. Turn the keyswitch to the OFF position. Repair: Repair any faulty connectors or replace the wir-
ing harness. Ensure that all the seals are properly in
B. Thoroughly inspect the P2 connector and any other con- place and ensure that the connectors are correctly
nectors that are included in the application for this throttle coupled.
switch. Refer to Troubleshooting, “Electrical Connectors - In-
spect” for details. Use the electronic service tool to clear all logged diag-
nostic codes and verify that the repair eliminates the
C. Perform a 30 N (6.7 lb) pull test on each of the wires in the fault.
switch connector and the ECM connector that are associated
with the active diagnostic code. Result: All connectors, pins, and sockets are correctly
coupled and/or inserted. The harness is free of corro-
sion, abrasion, and pinch points.
D. Check the ground connection on the ECM for abrasions
and pinch points. Proceed to Test Step 2.

E. Check the harness for abrasion and pinch points from the
suspect sensor to the ECM.

2. Check Throttle Cab Switch Position on the Electronic Throttle switch status Result: The throttle switch is functioning correctly. If
Service Tool changes on the elec- there are logged diagnostic codes for the throttle switch,
tronic service tool the fault may be intermittent.
A. Connect the electronic service tool to the diagnostic
connector. Repair: Refer to Troubleshooting, “Electrical Connectors
- Inspect” to identify intermittent faults.
B. Turn the keyswitch to the ON position.
Result: Record the suspect input.
C. Observe the status of the throttle switch and the throttle in-
puts on the electronic service tool while moving the throttle Proceed to Test Step 3.
switch to each position.

3. Install a Jumper at the Throttle Switch Connector Status is ON with Result: The fault is in the throttle switch.
jumper installed
A. Disconnect the connector for the throttle switch. Repair: Install a replacement throttle switch.
Status is OFF with
B. Observe the status of the suspect throttle input on the elec- jumper removed Use the electronic service tool to clear all logged diag-
tronic service tool. nostic codes and verify that the repair eliminates the
fault.
C. Connect a suitable jumper wire between terminal 1 on the
throttle switch connector and the terminal for the suspect throt- Result: The fault is not in the throttle switch.
tle input.
Proceed to Test Step 4.
D. Observe the status of the suspect throttle input on the elec-
tronic service tool.

E. Remove the jumper wire.

(continued)

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 358 M0095947-10
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(Table 210, contd)

Troubleshooting Test Steps Values Results

4. Check the Harness for an Open Circuit Less than 2 Ohms Result: At least one of the resistance measurements is
greater than 2 Ohms. The fault is in the wiring between
A. Turn the keyswitch to the OFF position. the throttle switch and the P2 connector.

B. Disconnect the P2 ECM connector and the connector for Repair: Repair the faulty wiring or replace the faulty
the throttle switch. wiring.

C. Measure the resistance between each of the throttle switch Use the electronic service tool to clear all logged diag-
inputs and the appropriate terminal on the P2 connector. nostic codes and then verify that the repair has elimi-
nated the fault.
D. Measure the resistance between the return terminal on the
throttle switch and the “Switch Return” terminal on the P2 Result: All resistance measurements are less than 2
connector. Ohms.

Proceed to Test Step 5.

5. Check the Harness for a Short Circuit Greater than 1k Result: At least one of the resistance measurements is
Ohms less than 1k Ohms. There is a short in the harness be-
A. Turn the keyswitch to the OFF position. tween the throttle switch connector and the P2
connector.
B. Disconnect the P2 ECM connector and the connector for
the throttle switch. Repair: Repair the faulty wiring or replace the faulty
wiring.
C. Measure the resistance between the suspect input terminal
and all other terminals on the P2 connector. Use the electronic service tool to clear all logged diag-
nostic codes and verify that the repair eliminates the
D. Measure the resistance between the “Switch Return” termi- fault.
nal and all other terminals on the P2 connector.
Result: All resistance measurements are greater than
1k Ohms.

Contact the Dealer Solutions Network (DSN).

i08073049

Valve Position - Test

This procedure covers the following diagnostic

codes:
Table 211

Diagnostic Codes for the Valve Position Sensors

J1939 Code Code Description Comments

The Electronic Control Module (ECM) detects that the signal voltage for
27-3 EGR #1 Valve Position : Voltage Above Normal the NOx Reduction System (NRS) valve position sensor is greater than
4.8 V for 0.1 second.
The ECM detects that the signal voltage for the NRS valve position sen-
27-4 EGR #1 Valve Position : Voltage Below Normal
sor is less than 0.2 V for 0.1 second.
The ECM detects that the signal voltage for the intake throttle valve po-
51-3 Engine Throttle Position : Voltage Above Normal
sition sensor is greater than 4.8 V for 0.1 second.

(continued)

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 M0095947-10 359
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(Table 211, contd)

Diagnostic Codes for the Valve Position Sensors

J1939 Code Code Description Comments

The ECM detects that the signal voltage for the intake throttle valve po-
51-4 Engine Throttle Position : Voltage Below Normal
sition sensor is less than 0.2 V for 0.1 second.

Engine Turbocharger #1 Wastegate Drive : Voltage The ECM detects that the signal voltage for the turbocharger Electronic
1188–3
Above Normal Wastegate (EWG) position sensor is greater than 4.8 V for 0.1 second.

Engine Turbocharger #1 Wastegate Drive : Voltage The ECM detects that the signal voltage for the turbocharger EWG is
1188–4
Below Normal less than 0.2 V for 0.1 second.
Follow the troubleshooting procedure to identify the root cause of the fault.

Use this procedure to troubleshoot the position

sensors for the following valves:

• EGR valve
• Engine intake throttle valve

• Turbocharger electronic wastegate

Each position sensor is integral in the associated
valve. If the following procedure indicates a fault with
the position sensor, then the entire valve must be
replaced.
The following background information is related
to this procedure:
The troubleshooting procedures for the diagnostic
codes of each position sensor are identical. The 5
VDC sensor supply provides power to all 5 VDC
sensors. The sensor supply is output short circuit
protected. A short circuit to the battery will not
damage the circuit inside the ECM. The signal
voltage from the valve position sensors is supplied to
the appropriate terminal at the P1 or P2 ECM
connector.
Pull-up Voltage
The ECM continuously outputs a pull-up voltage on
the circuit for the sensor signal wire. The ECM uses
this pull-up voltage to detect an open in the signal
circuit. When the ECM detects a voltage above a
threshold, the ECM generates an open circuit
diagnostic code (XXXX-3).
If the sensor is disconnected, pull-up voltage
indicates that the wires are not open or shorted to
ground. The absence of pull-up voltage indicates an
open in the signal wire or a short to ground. If the
voltage is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.

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 360 M0095947-10
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Illustration 58 g06498479

Complete the procedure in the order in which the

steps are listed.

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 M0095947-10 361
Circuit Tests

Table 212
Troubleshooting Test Steps Values Results

1. Verify All Active and Recently Logged Diagnostic Diagnostic Result: None of the preceding diagnostic codes are active or
Codes codes recently logged.

A. Turn the keyswitch to the ON position. Repair: The fault may be intermittent. Refer to Troubleshoot-
ing, “Electrical Connectors - Inspect” to identify intermittent
B. Use the electronic service tool to perform the “Air System faults.
Motor Valves Verification Test” .
Result: One or more of the preceding diagnostic codes are ac-
C. Verify if any of the diagnostic codes that are listed in Table tive or recently logged.
211 are active or recently logged.
Proceed to Test Step 2.

2. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found.
or connector
A. Thoroughly inspect the connector for the suspect valve Repair: Repair the damaged wire or the damaged connector.
and the engine interface connector. Refer to Troubleshooting, Use the electronic service tool to clear all logged diagnostic co-
“Electrical Connectors - Inspect”. des. Verify that the repair eliminates the fault.

Result: All connectors, pins, and sockets are correctly con-

B. Perform a 30 N (6.7 lb) pull test on each of the wires that nected and/or inserted and the harness is free of corrosion, of
are associated with the suspect position sensor in the valve abrasion or of pinch points.
connector and the engine interface connector.
Proceed to Test Step 3.
C. Check the harness for abrasions and for pinch points from
the suspect valve back to the ECM.

Note: Do not disconnect the ECM connector at this stage.

The ECM can only be disconnected and reconnected 10
times before damage to the harness connector may occur.

3. Measure the Sensor Supply Voltage at the Valve Between 4.84 V Result: The measured voltage is not within the expected
Connector and 5.16 V range.

A. Turn the keyswitch to the OFF position. Proceed to Test Step 4.

B. Disconnect the suspect valve from the engine harness. Result: The measured voltage is within the expected range.

C. Turn the keyswitch to the ON position. Proceed to Test Step 5.

D. Measure the voltage at the harness connector for the valve

from the 5 VDC supply terminal of the position sensor to the
sensor ground terminal.

(continued)

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 362 M0095947-10
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(Table 212, contd)

Troubleshooting Test Steps Values Results

4. Measure the Supply Voltage at the Engine Interface Between 4.84 V Result: The voltage is within the expected range.
Connector and 5.16 V The fault is in the 5 VDC supply wire or the ground wire be-
tween the valve connector and the engine interface connector.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty wiring.
B. Disconnect the engine interface connector. Use the electronic service tool to clear all logged diagnostic co-
des and verify that the repair eliminates the fault.
C. Turn the keyswitch to the ON position.
Result: The voltage is not within the expected range.
D. Use a suitable voltmeter to measure the voltage at the en- The fault is in the 5 VDC supply wire or the ground wire be-
gine interface connector. Measure the voltage between the 5 tween the engine interface connector and the ECM.
VDC supply pin and the return pin for the suspect valve.
Repair: Repair the faulty wiring or replace the faulty wiring.
E. Reconnect the engine interface connector. Use the electronic service tool to clear all logged diagnostic co-
des and verify that the repair eliminates the fault.

5. Verify the Type of Active Diagnostic Code Diagnostic Result: A -4 diagnostic code is active.
codes
A. Turn the keyswitch to the ON position. Proceed to Test Step 6.

B. Use the electronic service tool to perform the “Air System Result: A -3 diagnostic code is active.
Motor Valves Verification Test” .
Proceed to Test Step 9.
C. Use the electronic service tool to check for active diagnos-
tic codes. Record all active diagnostic codes.

6. Create an Open Circuit at the Valve Connector Diagnostic Result: A -3 diagnostic code is active with the valve
codes disconnected.
A. Turn the keyswitch to the OFF position.
Repair: Reconnect the connector for the valve.
B. Disconnect the connector for the valve with the -4 diagnos- If the -4 diagnostic code returns, there is a short in the valve.
tic code. Install a replacement valve. Refer to Disassembly and Assem-
bly for the correct procedure.
C. Turn the keyswitch to the ON position. If the turbocharger EWG is replaced, use the electronic service
tool to perform the “Turbocharger Wastegate Actuator Re-
D. Use the electronic service tool to perform the “Air System placement Reset” .
Motor Valves Verification Test” . Check for an -3 diagnostic If the NRS valve is replaced, use the electronic service tool to
code. perform the “EGR Valve Replacement Reset” .
If the intake throttle valve is replaced, use the electronic serv-
E. Turn the keyswitch to the OFF position. ice tool to perform the “Engine Throttle Valve Replacement Re-
set” .
Use the electronic service tool to clear all logged diagnostic co-
des and verify that the repair eliminates the fault.

Result: There is still a -4 diagnostic code active with the valve

disconnected.

Proceed to Test Step 7.

(continued)

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 M0095947-10 363
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(Table 212, contd)

Troubleshooting Test Steps Values Results

7. Create an Open Circuit at the Engine Interface Diagnostic Result: A -3 diagnostic code is active with the engine interface
Connector codes connector disconnected.
The fault is in the wiring between the valve connector and the
A. Turn the keyswitch to the OFF position. engine interface connector.

B. Disconnect the engine interface connector. Repair: Repair the faulty wiring or replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic co-
C. Turn the keyswitch to the ON position. des and verify that the repair eliminates the fault.

D. Use the electronic service tool to perform the “Air System Result: A -4 diagnostic code is still active with the engine inter-
Motor Valves Verification Test” . Check for an -3 diagnostic face connector disconnected.
code.
Reconnect the engine interface connector. Proceed to Test
Note: Diagnostic codes for all the engine sensors will be ac- Step 8.
tive with the engine interface connector disconnected. Ignore
all other codes and only look for codes that relate to the sus-
pect sensor.

E. Turn the keyswitch to the OFF position.

8. Check the Signal Wire to the ECM for a Short Circuit Greater than 1k Result: At least one of the resistance measurements is less
Ohm than 1k Ohm.
A. Turn the keyswitch to the OFF position. The fault is in the wiring for the suspect sensor between the
engine interface connector and the P2 connector.
B. Disconnect the P2 connector from the ECM. Thoroughly
inspect the P2/J2 connectors for damage or corrosion. Refer Repair: Repair the faulty wiring or replace the faulty wiring.
to Troubleshooting, Electrical Connectors - Inspect. Use the electronic service tool to clear all logged diagnostic co-
des and then verify that the repair eliminates the fault.
C. Disconnect the engine interface connector. Result: All resistance measurements are greater than 1k
Ohm.
D. Use a suitable multimeter to measure the resistance be-
tween the suspect sensor signal terminal on the engine inter- Contact the Dealer Solution Network (DSN).
face connector (ECM side) and all other terminals on the
engine interface connector.

(continued)

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 364 M0095947-10
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(Table 212, contd)

Troubleshooting Test Steps Values Results

9. Create a Short Circuit at the Valve Connector Diagnostic Result: A -4 diagnostic code is active when the jumper is
codes installed.
A. Turn the keyswitch to the OFF position.
Repair: Reconnect the connector for the suspect valve.
B. Disconnect the connector for the valve with the -3 diagnos- Turn the keyswitch to the ON position. Use the electronic serv-
tic code. ice tool to check for active diagnostic codes.
If the -3 diagnostic code returns, there is an open circuit in the
C. Fabricate a jumper wire that is 150 mm (6 inch) long. valve.
Install a replacement valve. Refer to Disassembly and Assem-
D. Insert one end of the jumper wire into the terminal for the bly for the correct procedure.
valve position sensor signal on the harness connector for the If the turbocharger EWG is replaced, use the electronic service
suspect valve. Insert the other end of the jumper into the ter- tool to perform the “Turbocharger Wastegate Actuator Re-
minal for the sensor ground on the harness connector for the placement Reset” .
suspect valve. If the NRS valve is replaced, use the electronic service tool to
perform the “EGR Valve Replacement Reset” .
E. Turn the keyswitch to the ON position. If the intake throttle valve is replaced, use the electronic serv-
ice tool to perform the “Engine Throttle Valve Replacement Re-
F. Use the electronic service tool to perform the “Air System set” .
Motor Valves Verification Test” . Check for an active -4 diag- Use the electronic service tool to clear all logged diagnostic co-
nostic code for the suspect sensor. des and verify that the repair eliminates the fault.

G. Turn the keyswitch to the OFF position. Result: A -3 diagnostic code remains active when the jumper
H. Remove the jumper. is installed.

Proceed to Test Step 10.

10. Create a Short Circuit at the Engine Interface Diagnostic Result: A -4 diagnostic code is active when the jumper is
Connector codes installed.
The fault is in the wiring between the valve connector and the
A. Turn the keyswitch to the OFF position. engine interface connector.

B. Disconnect the engine interface connector. Repair: Repair the faulty wiring or replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic co-
C. Fabricate a jumper wire that is 150 mm (6 inch) long. In- des and verify that the repair eliminates the fault.
stall the jumper between the suspect sensor signal terminal
and the sensor ground terminal on the engine interface con- Result: The -3 is still active with the jumper installed.
nector (ECM side).
Reconnect the engine interface connector. Proceed to Test
D. Turn the keyswitch to the ON position. Do not attempt to Step 11.
start the engine.

E. Use the electronic service tool to perform the “Air System

Motor Valves Verification Test” .Check for an active -4 diag-
nostic code.
Note: Diagnostic codes for all the engine sensors will be ac-
tive with the engine interface connector disconnected. Ignore
all other diagnostic codes and only look for codes that relate
to the suspect sensor.

F. Turn the keyswitch to the OFF position.

G. Remove the jumper wire.

11. Check the Signal Wire to the ECM for an Open Circuit Less than 2 Result: The measured resistance is greater than 2 Ohms.
Ohms The fault is in the wiring for the suspect sensor between the
A. Turn the keyswitch to the OFF position. engine interface connector and the P2 connector.

Repair: Repair the faulty wiring or replace the faulty wiring.

(continued)

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 M0095947-10 365
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(Table 212, contd)

Troubleshooting Test Steps Values Results
B. Disconnect the P2 connector from the ECM. Thoroughly Use the electronic service tool to clear all logged diagnostic co-
inspect the P2/J2 connectors for damage or corrosion. Refer des and verify that the repair eliminates the fault.
to Troubleshooting, Electrical Connectors - Inspect.
Result: The measured resistance is less than 2 Ohms.
C. Disconnect the engine interface connector.
Contact the DSN.
D. Use a suitable multimeter to measure the resistance be-
tween the suspect sensor signal terminal on the engine inter-
face connector and the suspect sensor signal terminal on the
P2 connector.

i07988094

Water in Fuel - Test

For a 97-15 code, refer to Troubleshooting, “Fuel

Contains Water” before returning to this procedure.
Use this procedure when the Water-In-Fuel sensor is
suspect. This procedure also covers the following
diagnostic code:
Table 213
Diagnostic Trouble Code for the Water-in-Fuel Sensor

J1939 Code Code Description Comments

97-3 Water In Fuel Indicator : Voltage Above The ECM detects the following conditions:
Normal
An open circuit in the Water-In-Fuel (WIF) sensor circuit.

The warning lamp will stay on when the “indicator lamp self check” has been
completed. The ECM will disable the function to detect water in fuel while the
code is active.

Water-in-Fuel Sensor Operation

The WIF sensor is a normally open sensor. During
normal operation, there will be no signal sent from
the WIF sensor to the ECM. If water is detected in the
fuel, the sensor will send a signal to the ECM. If the
signal remains constant for 5 seconds, a 97-15
diagnostic code will become active. If the signal
remains constant for 30 minutes, a 97-16 diagnostic
will become active. These diagnostic codes can also
be caused by a short in the WIF sensor circuit.

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Circuit Tests

Illustration 59 g06498535
Schematic diagram for the WIF sensor

Note: All connectors may not be shown. Refer to the

Electrical Schematic for the application for details of
any connectors between the WIF sensor connector
and the ECM connectors.

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Circuit Tests

Table 214
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection or Result: There is a fault in a connector or the wiring.
damaged wire
A. Turn the keyswitch to the OFF position. Repair: Repair any faulty connectors or replace the wir-
ing harness. Ensure that all the seals are properly in
B. Thoroughly inspect the connector for the WIF sensor and place and ensure that the connectors are correctly
any interface connectors between the WIF sensor and the coupled.
ECM connectors. Refer to Troubleshooting, “Electrical Con-
nectors - Inspect”. Use the electronic service tool to clear all logged diag-
nostic codes and verify that the repair eliminates the
C. Perform a 45 N (10 lb) pull test on each of the wires in the fault.
WIF sensor connector and any interface connectors that are
associated with the WIF sensor. Result: All connectors, pins, and sockets are correctly
coupled and/or inserted. The harness is free of corro-
sion, abrasion, and pinch points.
D. Check the harness for abrasions, for pinch points, and for
corrosion. Proceed to Test Step 2.

Note: Do not disconnect the ECM connector at this stage. The

ECM can only be disconnected and reconnected 10 times be-
fore damage to the harness connector may occur.

2. Check For Active Diagnostic Codes Diagnostic codes Result: There are no active diagnostic codes for the
WIF sensor.
A. Turn the keyswitch to the OFF position.
There may be an intermittent fault.
B. Connect the electronic service tool to the diagnostic Repair: Refer to Troubleshooting, “Electrical Connectors
connector. - Inspect” to identify intermittent faults.

C. Turn the keyswitch to the ON position. If the engine will Result: A 97-15 or 97-16 diagnostic code is active.
start, then run the engine.
Refer to Troubleshooting, “Fuel Contains Water” before
D. Wait for at least 1 minute. continuing with this procedure.

E. Monitor the active diagnostic code screen on the electronic Proceed to Test Step 3.
service tool. Check and record any active diagnostic codes.
Result: A 97-3 diagnostic code is active.

Proceed to Test Step 3.

3. Check the Supply Voltage at the Sensor Connector Between 11 V and 13 Result: The voltage is not within the expected range.
V for a 12 V system. The fault is in the sensor supply wire or the return wire .
A. Turn the keyswitch to the OFF position.
Between 22 V and 26 Repair: Repair the faulty sensor connector or replace
B. Disconnect the WIF sensor connector. V for a 24 V system the faulty harness.

C. Turn the keyswitch to the ON position. Use the electronic service tool to clear all logged diag-
nostic codes and verify that the repair eliminates the
D. Measure the voltage between the sensor supply and sen- fault.
sor return terminals on the harness connector for the WIF
sensor. Result: The voltage is within the expected range.

E. Turn the keyswitch to the OFF position. Reconnect the WIF sensor to the harness. Proceed to
Test Step 4.

(continued)

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(Table 214, contd)

Troubleshooting Test Steps Values Results

4. Check that the Diagnostic Code is Still Active Diagnostic code Result: A 97-3 diagnostic code is active.

A. Turn the keyswitch to the OFF position. Proceed to Test Step 5.

B. Connect the electronic service tool to the diagnostic Result: A 97-15 diagnostic code is active.
connector.
Proceed to Test Step 8.
C. Turn the keyswitch to the ON position. Wait for at least 1
minute. Result: No diagnostic code is active.

D. Monitor the active diagnostic code screen on the electronic Return the unit to service.
service tool. Check and record any active diagnostic codes.

5. Create a Short Circuit at the Sensor Connector Open circuit Result: A 97-3 diagnostic code was active before instal-
ling the jumper. A 97-15 code was active with the jumper
A.Turn the keyswitch to the ON position. Wait for at least 1 installed. There is an open circuit in the WIF sensor.
minute.
Repair: Install a replacement sensor. Refer to Disas-
B. Disconnect the WIF sensor from the harness. sembly and Assembly, “Water Separator and Fuel Filter
(Primary) - Remove and Install” for the correct
C. Fabricate a jumper wire that is 150 mm (6 inch) long. procedure.

D. Use the jumper to connect the sensor signal terminal to the Use the electronic service tool to clear all logged diag-
sensor return terminal on the harness connector for the WIF nostic codes and verify that the repair eliminates the
sensor. fault.

E. Monitor the active diagnostic code screen on the electronic Result: There is still an active 97-3 diagnostic code with
service tool. Check and record any active diagnostic codes. the jumper installed. The sensor is OK.

Proceed to Test Step 6.

6. Check the Wiring Between the WIF Sensor and the In- Less than 2 Ohms Result: The resistance is greater than 2 Ohms - There
terface Connector (if equipped) for an Open Circuit is a fault in the wiring between the WIF sensor connector
and the interface connector.
Note: This step is only applicable if an interface connector is
installed between the WIF sensor and the ECM. Refer to the Repair: Repair the faulty wiring or replace the faulty
Electrical Schematic for the application for more information. wiring.
Proceed to Test Step 7 if no interface connector is installed.
Use the electronic service tool to clear all logged diag-
A. Turn the keyswitch to the OFF position. nostic codes and check that the repair eliminates the
fault.
B. Disconnect the connector for the WIF sensor. Disconnect
the interface connector between the WIF sensor and the Result:The measured resistance is less than 2 Ohms.
ECM.
Reconnect all connectors. Proceed to Test Step 7.
C. Use a suitable multimeter to measure the resistance be-
tween the sensor signal terminal on the WIF sensor harness
connector and the sensor signal terminal on the interface
connector.

(continued)

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(Table 214, contd)

Troubleshooting Test Steps Values Results

7. Check the Signal Wire to the ECM for an Open Circuit Less than 2 Ohms. Result: The measured resistance is greater than 2
Ohms. There is an open circuit in the wiring to the ECM.
A. Turn the keyswitch to the OFF position.
Repair: Repair the faulty wiring or replace the faulty
B. Disconnect the connector for the water-in-fuel sensor and wiring.
P1 connector. Thoroughly inspect the P1/J1 connector for
damage or corrosion. Refer to Troubleshooting, Electrical Use the electronic service tool to clear all logged diag-
Connectors - Inspect. nostic codes and verify that the repair eliminates the
fault.
C. Use a suitable multimeter to check the resistance of the
sensor signal wiring between the sensor connector and the P1 Result: The measured resistance is less than 2 Ohms.
connector.
Contact the Dealer Solutions Network (DSN).
D. Install the removed connectors.

8. Create an Open Circuit at the Sensor Connector Short circuit Result: A 97-15 diagnostic code remains active with the
WIF sensor connected. A 97-3 diagnostic code was ac-
A. Turn the keyswitch to the ON position. Wait for at least 1 tive after disconnecting the WIF sensor. There is a short
minute. in the WIF sensor.

B. Disconnect the WIF sensor from the harness. Install a replacement sensor. Refer to Disassembly and
Assembly, “Water Separator and Fuel Filter (Primary) -
C. Monitor the active diagnostic code screen on the electronic Remove and Install” for the correct procedure.
service tool. Check and record any active diagnostic codes.
Use the electronic service tool to clear all logged diag-
nostic codes and verify that the repair eliminates the
fault.

Result: The 97-15 diagnostic code is still active with the

WIF sensor disconnected. The WIF sensor is OK.

Proceed to Test Step 9.

(continued)

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(Table 214, contd)

Troubleshooting Test Steps Values Results

9. Check the Wiring Between the WIF Sensor and the In- Greater than 1 k Result: At least one of the resistance measurements is
terface Connector (if equipped) for a Short Circuit Ohm less than 1k Ohm. There is a fault in the wiring between
the WIF sensor connector and the interface connector.
Note: This step is only applicable if an interface connector is
installed between the WIF sensor and the ECM. Refer to the Repair: Repair the faulty wiring or replace the faulty
Electrical Schematic for the application for more information. wiring.
Proceed to Test Step 7 if no interface connector is installed.
Use the electronic service tool to clear all logged diag-
A. Turn the keyswitch to the OFF position. nostic codes and check that the repair eliminates the
fault.
B. Disconnect the WIF sensor connector. Disconnect the inter-
face connector between the WIF sensor and the ECM. Result: All measured resistances are greater than 1 k
Ohm.
C. Use a suitable multimeter to measure the resistance be-
tween the WIF sensor signal terminal on the interface connec- Reconnect all connectors. Proceed to Test Step 10.
tor and all other terminals on the interface connector.

10. Check the Harness for a Short Circuit Greater than 1k Ohm Result: At least one of the resistance measurements is
less than 1k Ohm. There is a short in the wiring to the
A. Turn the keyswitch to the OFF position. ECM.

B. Disconnect the WIF sensor from the harness. Disconnect Repair: Repair the faulty wiring or replace the faulty
the P1 connector. Thoroughly inspect the P1/J1 connector for wiring.
damage or corrosion. Refer to Troubleshooting, Electrical
Connectors - Inspect. Use the electronic service tool to clear all logged diag-
nostic codes and verify that the repair eliminates the
C. Use a multimeter to measure the resistance between the fault.
WIF sensor signal terminal on the P1 connector and all other
terminals on P1. Result: All resistance measurements are greater than
1k Ohm.
D. Reconnect the WIF sensor to the harness. Reconnect the
P1 connector. Contact the DSN.

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Service

Service DEF Coolant Diverter Valve Solenoid

Override
The override is used to check the solenoid and
diverter valve harness. This override will open the
i07838322 coolant diverter valve. This test can be used to verify
that the coolant diverter valve is working correctly.
Service Tool Features
This override will only enable with the engine running
at idle prior to the DEF system priming to operating
pressure.
Note: The most recent version of the electronic
service tool must be used when connecting to the DEF Dosing Injector Status Override
ECMs.
This override allows the user to test the electrical
circuit for the DEF injector. The override commands
Override Parameters the DEF injector to open. This override only operates
The override parameters screen has multiple when there is no engine speed.
overrides. The parameters control various functions
on the engine and the aftertreatment. These System Troubleshooting Settings
functions and features allow the technician to
troubleshoot different engine systems. The “System Troubleshooting Settings” screen will
allow overrides to be enabled.
Override Parameters Listed in the Engine
System Troubleshooting Settings Listed
ECM Menu
in the Engine ECM Menu
Aftertreatment #1 Intake NOx Level
Injection Disable Override
Sensor Power Supply Override
This override will allow the user to disable the
This override can be used during troubleshooting to injectors from activating when performing certain
reset the SCR intake NOx sensor without having to troubleshooting procedures.
cycle key power to the Engine ECM.
Active Diagnostic Codes
Aftertreatment #1 Outlet #1 NOx Level
The purpose of this screen is to show all the active
Sensor Power Supply Override diagnostic codes.

This override can be used during troubleshooting to Select the “Diagnostics” tab.
reset the SCR Outlet NOx Sensor without having to
cycle key power to the Engine ECM. Select the “Active Diagnostic Codes” tab.

Ether Starting Aid Override Tab Functions At Bottom of Screen

This override is used to confirm the correct operation Reset All

of the ether system. Remove the ether canister from
the system before testing the ether injection system. This tab will reset all the active codes.
Refer to Troubleshooting, “Ether Starting Aid - Test”.
The override requires that engine speed must be
zero. The override will be unavailable for a short Troubleshoot Code
duration if glow plugs are active.
This tab is not available. Refer to Troubleshooting,
“Diagnostic Trouble Codes” for further information.
Glow Plug Starting Aid Override
This override is used to check that the glow plugs are Troubleshoot Symptom
functioning correctly. The override requires that
engine speed must be zero. The override will be This tab is not available. Refer to Troubleshooting,
unavailable for a short duration if ether injection is “Diagnostic Trouble Codes” for further information.
active.
Logged Diagnostic Codes
The purpose of this screen is to show all the logged
diagnostic codes.

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Select the “Diagnostics” tab. Troubleshoot Code

Select the “Logged Diagnostic Codes” tab. This tab is not available. Refer to Troubleshooting,
“Diagnostic Trouble Codes” for further information.
Tab Functions At Bottom of Screen
Troubleshoot Symptom
Clear This tab is not available. Refer to Troubleshooting,
This tab will clear specific codes when highlighted. “Diagnostic Trouble Codes” for further information.

Clear All
Diagnostic Tests
Electronic service tool diagnostic tests are listed
This tab will clear all logged diagnostic codes. below.
Select the “Diagnostics” tab.
Troubleshoot Code
Select the “Diagnostic Tests” tab.
This tab is not available. Refer to Troubleshooting,
“Diagnostic Trouble Codes” for further information.
Diagnostic Tests Listed in the Engine
Troubleshoot Symptom ECM Menu
This tab is not available. Refer to Troubleshooting, Injector Solenoid Test
“Diagnostic Trouble Codes” for further information.
The purpose of the injector solenoid test is to
Active Event Codes diagnose injector wiring and injector solenoid
The purpose of this screen is to show all the active functionality.
event codes.
This test identifies an open circuit or a short circuit in
Select the “Diagnostics” tab. the circuit for the injector solenoids. The test
activates the injector solenoids one at a time while
Select the “Events” tab. the engine is not running. A good solenoid will create
an audible click when the solenoid is activated. The
Tab Function At Bottom of Screen electronic service tool indicates the status of the
solenoid as “OK” , “Open” , or “Short” .

Reset All The injectors must be powered to enable the

automatic test to be run. To start the test, select the
This tab will reset all the active codes. Some of the “Start” button. The automatic test will continually
event codes will “latch” to active status. Repairing the cycle through the injectors until the “Stop” button is
system will not “unlatch” the event codes and the selected.
event codes must be reset with the electronic service
tool. There are no test results if the “Change” button is
selected to power or cutout an individual injector.
When selected, the “Power All” and “Cutout All”
Logged Event Codes buttons do not give test results.
The purpose of this screen is to show all the logged
event codes. Cylinder Cutout Test
Select the “Diagnostics” tab. The cylinder cutout test allows one cylinder or
Select the “Events” tab. multiple cylinders to be deactivated. The cylinder
cutout test is useful when troubleshooting poor
Select the “Logged Events” tab. engine performance or a suspected injector failure
when used after a cylinder compression test.
Tab Functions At Bottom of Screen The process involves cutting out power and restoring
power to a selected cylinder. The remaining powered
Clear cylinders are then monitored for expected increases
in delivered fuel volume. If the fuel volume does not
This tab will clear specific codes when highlighted. increase, the cylinder that was not powered was not
working prior to being cut out for the test.
Clear All
This tab will clear all logged diagnostic codes.

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A cylinder that is not working means that the power (Table 215, contd)
produced by that cylinder is comparatively less than Delivered Fuel Volume
the other cylinders. This fault can have numerous Cylinder Cutout
(Cubic Millimeters)
root causes relating to the cylinder including the
injector, valves, and piston. Cylinder 5 51.8

The cylinder cutout test can be performed Cylinder 6 50.8

automatically or manually. This function provides a
way to identify misfiring cylinders when the engine is All cylinders powered 41
running.
Table 215 shows an example of when all cylinders
Automatic Cylinder Cutout Test are operating normally. The delivered fuel volumes
are all similar. When a cylinder is cut out, the fuel
Engine speed and load need to be constant and delivery increases due to the loss of power from the
stable for the “Automatic Cylinder Cutout Test” cylinder and an additional increase in delivered fuel
average fuel measurements to be accurate. Changes volume to overcome the pumping losses of the cut
in engine speed and load due to auxiliary equipment out cylinder.
during the test may lead to inaccurate results.
If a cylinder that is weak is cut out, the fuel increase
From the “Diagnostics” menu, select “Diagnostic is less than cutting out a cylinder that is operating
Tests” , then “Cylinder Cutout Test” . Click start to run normally.
the “Automatic Cylinder Cutout Test” . The automatic Table 216
test will cut out power and restore power to each
Delivered Fuel Volume
cylinder in turn, measuring the average fuel delivery Cylinder Cutout
(Cubic Millimeters)
when each cylinder is cut out.
Cylinder 1 55.5
Perform the “Automatic Cylinder Cutout Test” with the
engine at approximately 50 percent load condition. Cylinder 2 55
Running the engine with some load applied will
amplify the effects of any faults and make a fault Cylinder 3 55.5
easier to detect. If the engine load is too high, the Cylinder 4 54
vibration will be increased and the engine may stall.
Cylinder 5 56
Fuel measurements have successfully been taken
when the test has completed. Save the “Cylinder Cylinder 6 42.4
Cutout Test” results for future reference.
All cylinders powered 42.4

Evaluating the “ Automatic Cylinder

Table 216 shows an example of cylinder 6 not
Cutout Test”” Fuel Measurements producing any power. The delivered fuel volume
when cylinder 6 is cut out is the same as the
The “Automatic Cylinder Cutout Test” does not delivered fuel volume when all cylinders are
provide a pass/fail criteria. At the end of the test, the powered.
delivered fuel volume for each cylinder will be
provided. If a cylinder that is strong is cut out, the fuel increase
will be more than if a cylinder that is operating
The delivered fuel volume is displayed in units of normally is cut out.
cubic millimeters of governor requested fuel. When a
Table 217
cylinder is cut out, the governor fuel will increase the
requested fuel for the other powered injectors to Delivered Fuel Volume
compensate. Cylinder Cutout
(Cubic Millimeters)
Table 215
Cylinder 1 56.8
Delivered Fuel Volume
Cylinder Cutout Cylinder 2 56.3
(Cubic Millimeters)
Cylinder 1 51.3 Cylinder 3 56.8

Cylinder 2 50.8 Cylinder 4 59.1

Cylinder 3 51.3 Cylinder 5 57.3

Cylinder 4 49.8 Cylinder 6 57.3

All cylinders powered 47.3

(continued)

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Table 217 shows an example of cylinder 4 producing The Wiggle Test will reduce all ECM requirements to
approximately 25% more power the other cylinders trip fault codes, making the diagnostics sensitive.
which are operating normally. The delivered fuel Under normal operation some fault codes need
volume when cylinder 4 is cut out is higher than the multiple occurrences before the code will log. But
delivered fuel volume when all the other cylinders are during this test the fault codes will trip the first time.
cut out.
The technician must wiggle and shake the wiring to
check if codes go active. If any parameter changes
Manual Cylinder Cutout Test state electrically, an audible alarm is also activated.
Once the test has ended, the ECM returns to normal
The “Manual Cylinder Cutout Test” is available as a diagnostic trip requirements.
method to manually cutout a cylinder to investigate
issues such as “Engine Misfires Runs Rough or is
Unstable” or “Engine Vibration is Excessive” . Fuel Rail Pressure Relief Valve Test
The “Manual Cylinder Cutout” can be performed on The purpose of this test is check that the opening
one injector or multiple injectors at once. This pressure for the pressure relief valve is above
function provides a way to identify misfiring cylinders 220 MPa (31900 psi). The engine speed is
when the engine is running. automatically increased above a minimum threshold
when this test is run and then the rail pressure is
From the “Diagnostics” menu, select “Diagnostic increased to 220 MPa (31900 psi). After a short time,
Tests” , then “Cylinder Cutout Test” . Select a cylinder the rail pressure is reduced to normal.
to cut out, then click “Change” . The status of the
selected cylinder will change from “Powered” to Fuel Rail Pressure Test
“Cutout” . Click “Change” again to change the status
back to “Powered” . The purpose of this test is to check the integrity of the
high-pressure fuel system after work has been
Note: More than one cylinder can be cut out completed. The test can also help with
simultaneously, but cutting out too many cylinders troubleshooting general fuel system-related issues.
may result in the engine stalling.
The engine speed is automatically increased above a
Click “Power All” to power all the cylinders. minimum threshold when this test is run. The rail
pressure is increased to 200 MPa (29008 psi) and
When a cylinder is cut out, the engine noise, held at this pressure for a time. The rail pressure is
vibration, or smoke can be observed to help then reduced to normal. If the check is for system
determine whether an individual cylinder is the cause integrity after work, the engine must be shut down
of an issue. before inspecting the high-pressure fuel system for
fuel leaks. If the reason for the test is troubleshooting
Perform a cylinder compression test to isolate general fuel system-related issues, check for error
injector faults from a malfunctioning cylinder. If a codes. Any error codes that occur during the test
cylinder passes the compression test, there may be a should be used to provide guidance for
faulty injector. If a cylinder fails a compression test, troubleshooting.
there may still be a faulty injector which has damaged
the cylinder, such as damage from over- fueling.
Refer to Systems Operation, Testing and Adjusting, Aftertreatment Regeneration System Test
Compression - Test.
Before performing this test, make sure that loads that
can cause power fluctuations are inhibited. An
Wiggle Test example of a fluctuating load is air conditioning.
The purpose of the Wiggle Test is to detect This test must be run with the engine running but not
intermittent electrical faults in electronic control under load. The engine must reach a minimum
systems. The Wiggle Test function allows the user to coolant temperature. Once the conditions are met,
determine if there is an intermittent wiring fault. The engine speed and load must be reduced to the
test will indicate (by changing the value reading) minimum level that can be achieved with the engine/
which parameter moved beyond a predetermined equipment configuration.
range while wiggling the wiring harness, sensor, or
connector. The ECM software performs the necessary checks to
ensure that the test runs under the required
This test requires that the engine is OFF and the key conditions. If the test aborts before completion, the
switch is in the ON position (or ECM energized and 0 electronic service tool displays any relevant error
engine speed). If the engine is started with the wiggle identifiers.
test active, the wiggle test will abort.
The following conditions must be met before the
Aftertreatment Regeneration System Test can begin:

• No related active diagnostic codes

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• Coolant at the minimum required temperature Engine Throttle Valve Replacement Reset
• Engine speed and load in the required range The engine intake throttle valve minimum and
maximum positions are calibrated automatically at
The ECM will gradually close the engine Intake each key off and stored in the ECM Non-Volatile
Throttle Valve (ITV) to establish a desired Intake Memory (NVM) to ensure accurate range over the life
Manifold Air Pressure (IMAP) setpoint. If the desired of the product. Engine intake throttle valve usage
IMAP setpoint is not achieved, an error identifier will information is also stored in NVM. After replacement
be displayed, indicating that the intake manifold of the engine intake throttle valve, the “Engine
pressure is too high. Throttle Valve Replacement Reset” should be run to
reset the minimum and maximum position
If the desired IMAP setpoint is achieved, the test will calibrations to the nominal values and reset the
wait for the DPF intake temperature to stabilize. The usage information. Run the “Air System Motor Valve
test will then check if the DPF intake temperature is Verification Test” to recalibrate the specific minimum
above a minimum threshold. If the minimum and maximum positions for the new engine intake
temperature threshold is not met, an error identifier throttle valve.
will be displayed to indicate that the DPF intake
temperature is too low. 1. Connect to the electronic service tool.
Note: If the DPF intake temperature is too low or the 2. Select the engine ECM.
desired IMAP cannot be reached, the engine speed
will be increased and the test will begin again. If the 3. Select the “Service” tab.
desired IMAP or DPF intake temperature still cannot 4. Select the “Engine Throttle Valve Replacement
be reached, the test will be aborted and the Reset” feature.
appropriate identifier will be displayed.

Air System Motor Valves Verification Test

The “Air System Motor Valve Verification Test” will
identify whether the NRS valve, the intake throttle
valve, and the turbocharger EWG are working
correctly. This test must be performed when the
engine speed is zero and the battery voltage is within
an acceptable range. For a 12V system, the test must
only be performed when the battery voltage is
between 9V and 16V. For a 24V system, the test
must only be performed when the battery voltage is
between 18V and 32V. If the battery voltage is out of
the required range, the test will be aborted.
The “Air System Motor Valve Verification Test” will
actively check position sensor diagnostics, motor
short diagnostics, and motor open circuit diagnostics.
The test will abort if any of these diagnostic codes
become active.
If the engine speed is not zero while the test is being
performed, the test will be aborted. If no electrical
diagnostic codes are active, the test will calibrate the
NRS valve minimum position, the intake throttle valve
minimum and maximum position, and the
turbocharger EWG maximum position. The test then
moves the valves to various positions and checks the
position sensor within each valve to confirm that the
valve has responded correctly. Each valve will be
tested in turn, starting with the NRS valve. If a test
threshold is exceeded or any related diagnostic
codes become active, the test will abort and generate
a service tool error identifier.

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Illustration 60 g06518168

The screen will display the current minimum and

maximum position calibrations and usage
information:

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Service

Illustration 61 g06518172

When the “Reset” button is selected, a warning

message is displayed which must be accepted before
the reset is triggered. Only perform this function after
replacement of the Engine Intake Throttle Valve, as
the loss of usage information and could negatively
impact engine performance. Selecting “Yes” will
command the service tool to request that the ECM
resets this information:

Illustration 62 g06518197

After the reset has completed, a “Reset was

successful” message will be displayed on the screen:

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Illustration 63 g06518201

After selecting “OK” , the minimum and maximum

position calibrations and usage information will be
read again from the ECM and displayed in the reset
feature. All will be 0, confirming the reset was
successful:

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Service

Illustration 64 g06518204

EGR Valve Replacement Reset

The EGR valve minimum position is calibrated
automatically at each key off and stored in the ECM
Non-Volatile Memory (NVM) to ensure accurate
range over the life of the product. EGR valve usage
information is also stored in NVM. After replacement
of the EGR valve, the “EGR Valve Replacement
Reset” feature should be run to reset the minimum
position calibration to the nominal value and reset the
usage information. Run the “Air System Motor Valve
Verification Test” to recalibrate the specific minimum
position for the new EGR Valve.
1. Connect to the electronic service tool.
2. Select the engine ECM.
3. Select the “Service” tab.
4. Select the “Engine EGR Valve Replacement
Reset” feature.

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Illustration 65 g06518207

The screen will display the current minimum and

maximum position calibrations and usage
information:

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Service

Illustration 66 g06518217

When the “Reset” button is selected, a warning

message is displayed which must be accepted before
the reset is triggered. This function should only be
run after replacement of the EGR Valve, as the loss
of usage information and could negatively impact
engine performance. Selecting “Yes” will command
the service tool to request that the ECM resets this
information:

Illustration 67 g06518197

After the reset has completed, a “Reset was

successful” message will be displayed on the screen:

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Illustration 68 g06518201

After selecting OK, the minimum and maximum

position calibrations and usage information will be
read again from the ECM and displayed in the reset
feature. All will be 0, confirming the reset was
successful:

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Illustration 69 g06518221

Turbocharger Wastegate Actuator

Replacement Reset
The turbocharger wastegate actuator maximum
position is calibrated automatically at each key off
and stored in the ECM Non-Volatile Memory (NVM),
to ensure accurate range over the life of the product.
Turbocharger wastegate actuator usage information
is also stored in NVM. After replacement of the
turbocharger wastegate actuator, the “Turbocharger
Wastegate Actuator Replacement Reset” feature
should be run to reset the maximum position
calibration to the nominal value and reset the usage
information. Run the “Air System Motor Valve
Verification Test” to recalibrate the specific maximum
position for the new turbocharger wastegate actuator.
1. Connect to the electronic service tool.
2. Select the engine ECM.
3. Select the “Service” tab.
4. Select the “Turbocharger Wastegate Actuator
Replacement Reset” feature.

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Illustration 70 g06518243

The screen will display the current minimum and

maximum position calibrations and usage
information:

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Illustration 71 g06518245

When the “Reset” button is selected, a warning

message is first displayed which must be accepted
before the reset is triggered. Only run this function
after replacement of the turbocharger wastegate
actuator, as the loss of usage information and could
negatively impact engine performance. Selecting
“Yes” will command the service tool to request that
the ECM resets this information:

Illustration 73 g06518201

After selecting “OK” , the minimum and maximum

position calibrations and usage information will be
read again from the ECM and displayed in the reset
feature. All will be 0, confirming the reset was
successful:

Illustration 72 g06518197

After the reset has completed, a “Reset was

successful” message will be displayed on the screen:

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Illustration 74 g06518247

Engine Turbocharger #1 Estimated

Efficiency Loss Reset
For Engines with a closed-circuit Breather
configuration, the “Estimated Turbocharger #1
Efficiency Loss %” is modeled and stored in the ECM
Non-Volatile Memory (NVM) to maintain an accurate
estimation over the life of the product. After cleaning
or replacement of the turbocharger, the “Engine
Turbocharger #1 Estimated Efficiency Loss Reset”
feature should be run to reset the estimated
efficiency loss to 0%. This feature does not apply to
engines with an Open-Circuit Breather Configuration.
1. Connect to the electronic service tool.
2. Select the engine ECM.
3. Select the “Service” tab.
4. Select the “Engine Turbocharger #1 Estimated
Efficiency Loss Reset” .

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Illustration 75 g06521581

The screen will display the current estimated

turbocharger efficiency loss %:

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Illustration 76 g06521611

When the “Reset” button is selected, a warning

message is first displayed which must be accepted
before the reset is triggered. Only perform this
function after the turbocharger cleaning procedure
has been run or after replacement of the
turbocharger, as loss of usage information and could
negatively impact engine performance. Selecting
“Yes” will command the service tool to request that
the ECM resets this information:

Illustration 78 g06518201

After selecting “OK” , the engine turbocharger

estimated efficiency loss will be read again from the
ECM and displayed in the reset feature. A value of 0
confirms that the reset was successful:

Illustration 77 g06518197

After the reset has completed, a “Reset was

successful” message will be displayed on the screen:

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Illustration 79 g06521637

Aftertreatment System Functional Test Once the target SCR inlet temperature has been
achieved and the NOx conversion level has been
Before performing this test, make sure that loads that met, the test will complete successfully.
can cause power fluctuations are inhibited. An
example of a fluctuating load is air conditioning. If a related diagnostic code is generated during the
test, the test will be aborted.
This test is used to verify that the SCR System is
If the test times out with no active codes and NOx
functioning correctly. The engine intake throttle valve conversion test criteria is not met, a low NOx
and elevated engine speed are used to increase the conversion error identifier is logged.
exhaust gas temperature. The higher temperature
allows the NOx sensors and SCR system to control If an active low DEF concentration event or low NOx
active DEF dosing. conversion ratio event is present, the test will be
modified. This mode will request that DEF dosing be
When the NOx sensors are ready for use, the reduced to a minimum to remove all stored ammonia
sensors control DEF dosing and check that the NOx in the catalyst. The test will then attempt to clear the
conversion efficiency meets the test target value. NOx conversion and DEF concentration events in an
abbreviated time period. If the events are cleared, the
The following conditions must be met for the test to test will complete successfully. If the events are still
start: active, the test will fail after a timeout period.

• Coolant at the minimum required temperature Manual Hydrocarbon Dosing Capability

• DEF at the minimum required temperature Test
• Exhaust gas at the minimum required temperature Before performing this test, make sure that loads that
can cause power fluctuations are inhibited. An
• Sufficient DEF in the tank example of a fluctuating load is air conditioning.
• No related active diagnostic codes This test is used to check the HC dosing process.
Periodic HC dosing elevates the exhaust gas
• Engine speed and load in the required range temperature to clean the aftertreatment system.

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Note: For engines equipped with an SCR system, This test turns on all the line heaters. The test will
the test will check that HC dosing raises the SCR cycle the line heaters on and off for 5 minutes. After 5
intake temperature to the correct level. For engines minutes, the test will turn off. This test is used to
without the SCR system equipped, the test will check check the line heater circuit for faults.
that HC dosing raises the DPF intake temperature to
the correct level. DEF Dosing System Verification Test
The test must be performed at low engine speed and This test primes the dosing system. The test is used
low load. The test will only start when all the following to ensure that the DEF pump is able to build
criteria are met: adequate pressure.
• The engine is running This test turns on the DEF pump for 5 minutes.
During this time, the DEF pump will pressurize the
• Coolant at the minimum required temperature entire DEF dosing system. The DEF injector will
remain closed to maintain a constant pressure within
• No active diagnostic codes the dosing system. The DEF pump will purge the
system at the end of the test.
Note: Engine speed may be automatically increased
until the desired conditions are met.
Cooling System Capacity Test
The test will use the Intake Throttle Valve (ITV) to
increase the DOC intake temperature. When the This test is only used as part of the application and
target DOC inlet temperature is reached, HC dosing installation process.
will be initiated automatically. The test will check for
adequate heat rise across the DOC during HC dosing Aftertreatment System Temperature Drop
ignition phase. If the required temperature rise is
achieved, HC dosing will increase until the DPF Assessment Test
intake temperature reaches approximately 475° C
(887° F). If the DOC intake temperature is too low, This test is only used as part of the application and
the test may increase the engine speed to elevated installation process.
idle speed. If the engine speed has already been
elevated, the test will abort with an error identifier. If Calibrations
the target SCR intake temperature is achieved, the
test will end successfully. Electronic service tool calibration procedures are
listed below.
DEF Dosing System Accuracy Test In the electronic service tool, select the engine ECM.

This test is used to measure the amount of DEF that Select the “Service” tab.
the SCR dosing system is delivering. The test can Select the “Calibrations” tab.
also be used to confirm that there is an acceptable
spray pattern from the DEF Injector.
Calibrations Listed in the Engine ECM
Note: The DEF injector must be removed from the
exhaust system during this test and placed in an
Menu
appropriate container. Failure to do so could result in
issues with the SCR system operation. Refer to Injector Codes Calibration
Systems Operation, Testing, and Adjusting,
“Aftertreatment SCR System Dosing Test”. Whenever an injector is replaced, the injector must
be trimmed. Trimming the injector calibrates all the
This test turns on the DEF pump and opens the DEF injectors to deliver the same amount of fuel. The
injector. The DEF injector atomizes the DEF and the injector trim code is on the injector. The Injector
spray pattern must be uniform in order for the SCR Codes Calibration allows the injector trim code
system to work correctly. Once the test completes, information to be programmed into the ECM. After
the system will purge and the amount of DEF in the the injector is calibrated, the calibration data is
container must be confirmed to meet the checked for validity. For further information, refer to
specification. Troubleshooting, “Injector Code - Calibrate”.

DEF Heated Lines Test

This test checks the electrical circuit integrity by
activating the line heaters. The test is used to
validate a repair made to any of the heated line
circuits.

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High Pressure Fuel Pump Calibration

High-pressure fuel pump calibration is used to
perform a pump calibration manually. In normal
operation, this calibration procedure will occur
automatically. The calibration must only be
performed as instructed during troubleshooting
procedures. The pump calibration is used to optimize
the dynamic characteristics of the rail pressure
control. If there are issues with overshooting or
undershooting the desired rail pressure, a pump
calibration will improve the rail pressure control.

Dyno Mode
In the electronic service tool, select the engine ECM.
Select the “Service” tab.
Select the “Dyno Mode” tab.

Dyno Mode
When the engine is installed in a machine, the engine
ECM receives inputs from various machine
components, such as the transmission ECM or
machine ECM. If the ECM does not see the inputs,
the ECM assumes that something is wrong and sets
a diagnostic trouble code.
Dyno Mode is used to run an engine on a
dynamometer without derates or diagnostic trouble
codes tripping from missing inputs. Dyno Mode does
not require the CEM to be installed.
1. Select “Enable” to enable Dyno Mode.
2. Return to the “Service” tab.
3. Select the “Service Procedures” tab.

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Illustration 80 g03826879

4. Select the “Powertrain Protection Reset” (

Available on select models).

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Illustration 81 g03826882

5. Select “Reset Protection” .

If the engine has multiple power ratings, select the
highest rating.

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Illustration 82 g03826884

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Illustration 83 g03826886

Service Procedures This procedure is used specifically for engines which

Electronic service tool service procedures are listed require periodic HC dosing to clean the
below. aftertreatment system to remove SCR deposits and/
or to reduce DPF soot load. The test is performed at
In the electronic service tool, select the engine ECM. elevated temperatures so that acceptable NOx
conversion is maintained. The purpose of the
Select the “Service” tab. procedure is to recover performance of the complete
aftertreatment system.
Select the “Service Procedures” tab.
The ECM software will perform the necessary checks
Service Procedures Listed in the Engine to ensure that the procedure runs under the required
conditions. The checks will generate any relevant
ECM Menu error identifiers if the procedure aborts before
completion.
Aftertreatment Recovery Procedure The following engine conditions must be met before
the procedure will start:
Before performing this test, make sure that loads that
can cause power fluctuations are inhibited. An • No related active diagnostic codes
example of a fluctuating load is air conditioning.
• Coolant temperature condition met
• Engine speed and load in the required range

• DPF Soot load is not too high

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If the engine speed is not within the desired range, Service Tool Error Identifiers
engine speed may be automatically adjusted to Error identifiers are displayed when an electronic
approximately 1700 rpm. When the required
service tool service test has failed. The error
conditions are met, the procedure assesses the DPF identifiers explain the reason for the service test
soot load. If soot loading is too high to allow HC failure. The service test error identifier may identify
Dosing, the procedure will use elevated idle and the the failed component. For a list of error identifiers,
engine intake throttle valve to reduce the soot load. refer to Troubleshooting, “Service Tool Error
The procedure will target a specific desired intake Identifiers”. If necessary, refer to the troubleshooting
manifold air pressure. guide for the appropriate troubleshooting procedure.
The procedure also checks that the DPF intake
temperature is above a minimum pass threshold. If Aftertreatment History
the minimum temperature threshold is not met, an Connect to the electronic service tool.
error identifier is displayed, indicating that the DPF
intake temperature is too low. Once the system Select the Engine ECM.
verification steps are complete, the procedure will
continue to run for a set time to desulfate the DPF. Select the Information tab.
If the soot load is reduced sufficiently, the procedure
will start HC dosing and assesses whether the Aftertreatment Abnormal Shutdown
system can generate the required aftertreatment History
temperature. On engines equipped with SCR, the
procedure will target an SCR intake temperature This feature allows the user to see when the engine
required to remove any urea or sulfur deposits from was shut down incorrectly. This screen shows hot
the aftertreatment. On engines without SCR, the shutdown events, and cold shutdown events.
procedure will target a DPF intake temperature
required to reduce soot load below the required level. A hot shutdown can damage the aftertreatment or
A higher than normal DOC intake temperature is SCR system.
targeted to ensure that light-off occurs first time.
A cold shutdown can damage the SCR dosing
If the target DOC intake temperature is reached, HC system.
dosing will be initiated automatically. The procedure
will check for adequate heat rise across the DOC Hydrocarbon Dosing History
during the HC dosing ignition phase. If the
temperature rise is not sufficient, the procedure will
perform the DPF desulfation procedure before Connect to the electronic service tool.
attempting HC Dosing again. If the DOC fails to ignite Select the Engine ECM.
again, the procedure will abort with an error identifier.
Select the Information tab.
Note: If DPF desulfation had been previously
performed due to high soot load, the test will abort Select History
immediately with an error identifier. HC dosing will
not be attempted. Select the Hydrocarbon Dosing History

If the heat rise target is achieved, the procedure will The ECM logs timestamp and engine data at the start
continue to increase the amount of HC dosing until and end of an HC dosing regeneration. Data can be
the DPF intake temperature stabilizes at the target viewed using the electronic service tool to analyze
value of approximately 475° C (887° F). the process when HC dosing occurs.

If this part of the procedure is successful, HC dosing Snapshots

will continue until the required SCR intake
temperature or the required DPF intake temperature Snapshots are only available for specific system
is achieved. The procedure then maintains this faults. Other faults will not trigger a snapshot.
temperature for a set time to remove sulfur and/or
urea deposits from the SCR catalyst. Snapshots record data for a predefined time before
and after a diagnostic trouble code or event code is
If the soot load has not sufficiently reduced, the test triggered and store the data in the ECM.
will abort with an error identifier.
Only data for the most recent occurrence of the fault
code is stored in the snapshot. Data from the
previous snapshot occurrence will be overwritten.
The data must be downloaded before either clearing
codes or before taking troubleshooting action.

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A service technician should not interpret snapshot (Table 218, contd)

data via the service tool in the field. Without specialist
J1939 Code and Description
control system knowledge the data can be easily
misinterpreted. 656-5
Engine Injector Cylinder #06 : Current Below Normal
Download the data using the electronic service tool
and supplied back to the Dealer Solutions Network 656-6
(DSN) when requested for analysis. Engine Injector Cylinder #6: Current Above Normal

1. Select the “Information” tab. Select the “Snapshot” 174-3

tab and then select the “Viewer” tab. Engine Fuel Temperature 1 : Voltage Above Normal

The following diagnostic codes and event codes 174-4

Engine Fuel Temperature 1 : Voltage Below Normal
will trigger snapshots.
Table 218 1076-5
Engine Fuel Injection Pump Fuel Control Valve : Current Below
J1939 Code and Description Normal
102-16 1076-6
Engine Intake Manifold #1 Pressure : High - moderate severity Engine Fuel Injection Pump Fuel Control Valve : Current Above
(2) Normal

102-18 174-16
Engine Intake Manifold #1 Pressure : Low - moderate severity Engine Fuel Temperature 1 : High - moderate severity (2)
(2)
157-16
2659-7 Engine Injector Metering Rail #1 Pressure : High - moderate se-
Engine Exhaust Gas Recirculation (EGR) Mass Flow Rate : Not verity (2)
Responding Properly
157-18
157-3 Engine Injector Metering Rail #1 Pressure : Low - moderate se-
Engine Injector Metering Rail #1 Pressure : Voltage Above verity (2)
Normal
5571-0
157-4 High Pressure Common Rail Fuel Pressure Relief Valve : High -
Engine Injector Metering Rail #1 Pressure : Voltage Below most severe (3)
Normal
651-5
Engine Injector Cylinder #01 : Current Below Normal
Perform the following steps to download and save
snapshot data from the electronic service tool:
651-6
Engine Injector Cylinder #1: Current Above Normal

652-5
Engine Injector Cylinder #02 : Current Below Normal

652-6
Engine Injector Cylinder #2: Current Above Normal

653-5
Engine Injector Cylinder #03 : Current Below Normal

653-6
Engine Injector Cylinder #3: Current Above Normal

654-5
Engine Injector Cylinder #04 : Current Below Normal

654-6
Engine Injector Cylinder #4: Current Above Normal

655-5
Engine Injector Cylinder #05 : Current Below Normal

655-6
Engine Injector Cylinder #5: Current Above Normal

(continued)

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Illustration 84 g06395524

2. From the “Information” menu, select “Snapshot” ,

then select “Viewer” .

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Illustration 85 g06395559

3. Select the diagnostic trouble code or event code,

then click “View Graph” .

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Illustration 86 g06395572

4. From the available parameters, select the “Engine

Speed” parameter, then click “OK” .

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Illustration 87 g06395891

Illustration 88 g06395896

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5. Select “Save to File” and save the snapshot file (*.

xml). This file will contain all the data in the
snapshot and not only the “Engine Speed” data
shown on the graph.

Illustration 89 g03826908

Histogram Screens
Tab Functions At Bottom of Screen

Histograms
This tab pulls up the histogram menu.

Clear
This tab is currently not available.

Clear All
This tab will clear the current histogram data for this
key cycle.

Show All Labels

This labels all bars in the graph.

View Labels on Mouseover

This labels each bar in the graph as the mouse
pointer is moved over the bar.

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Screen Shots

Illustration 90 g03826913
The total number of occurrences.

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Illustration 91 g03826916
The amount of engine hours operated at indicated inlet temperature.

Illustration 92 g03826917
The amount of engine hours operated at indicated coolant temperature.

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Illustration 93 g03826918
The amount of engine hours operated at indicated engine speed.

Illustration 94 g03826920
The amount of engine hours operated at indicated intake manifold air temperature.

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Illustration 95 g03826921
The amount of engine hours operated at indicated intake manifold pressure.

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Illustration 96 g03826922
This screen is used to help understand the operator use of the disable switch and at what soot load the
regenerations take place. Manual disable status 0 = regenerations allowed due to switch position. Manual disable
status 1= regenerations not allowed due to switch position.

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Illustration 97 g03826923
This screen is used to illustrate load percentage at the current engine speed. This screen can be helpful in
understanding how the engine is being used. The screen can also be used for comparison between similar
machines and/or operators.

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Illustration 98 g03826926
This histogram is populated when the engine system has calculated a condition in which high exhaust
temperatures are present. A fault code for high exhaust temperature is not logged, but the engine will derate to
protect the engine system. This situation is normal under most circumstances and no additional troubleshooting is
necessary. Refer to Troubleshooting, “Exhaust Temperature is High” for additional information.

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Illustration 99 g03826928
There are certain engine conditions that risk turbocharger overspeed. The engine is calibrated and certified up to a
certain altitude and ambient temperature limit. If the engine is operated outside this limit, the engine is more likely to
experience overspeed of the turbo. This situation occurs because the turbo has to work harder to maintain the
desired boost pressure. This situation is normal under most circumstances and no additional troubleshooting is
necessary.

System Communication Status • Multi Position Throttle Switch (MPTS) which uses
up to four switch inputs giving a total of 16
Connect to the electronic service tool. combinations. Each switch combination can then
Select the engine ECM. be programmed with a desired engine speed,
which can be selected by the operator.
Select the “Diagnostics” tab.
The permitted throttle combinations are shown in the
This feature provides a means of troubleshooting following table:
J1939 data link issues. The feature shows which
modules are not responding and which data link
parameters are missing. Refer to Troubleshooting,
“Data Link - Test” for further information.

Throttle Mode Configuration

The throttle configuration screen allows the ECM to
be configured with up to two channel inputs. The
inputs can be a combination of three types of speed
control input. The three types of speed control input
are:
• PWM throttle input providing a variable duty cycle
input to control engine speed
• Analog throttle input providing a variable voltage
signal to control engine speed

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Table 219
Channel 1 Channel 2
None None
PWM None
None PWM
PWM PWM
Analog None

None Analog

Analog Analog

PWM Analog

Analog PWM

MPTS None
MPTS PWM
MPTS Analog

None MPTS
PWM MPTS
Analog MPTS

Note: The MPTS input can only be used on one

channel.
There is also the option of using an Idle Validation
Switch (IVS) on the analog throttle. This switch is
used to confirm that the throttle pedal has been
physically moved, before reacting to the analog
speed demand signal. The IVS and software logic is
designed to protect against signal faults which could
cause unintended engine speed increases.
Programming each throttle input requires some
technical knowledge of the throttle specification that
is being used. Knowledge is required to program the
specifications into the correct ECM parameter
values.

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Illustration 100 g03826943

Screen 1

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Illustration 101 g03826947

Screen 2

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Illustration 102 g03826949

Screen 3

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Illustration 103 g03826950

Screen 4

Engine Operating Mode

Configuration
The engine operating mode configuration feature
allows the configuration of up to four separate modes
that can be selected via two switch inputs.
If only one mode is required, no switch inputs are
required and Mode 1 will always be used.
If two modes are required, one switch input can be
selected to toggle between Mode 1 and Mode 2. If
three or four modes are required, two switch inputs
will be required. The numbers of switches are
selected in the drop-down box at the top of the
screen.

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Illustration 104 g03422567

Screen 1

Once the number of required modes and switches Once the mode configuration has been set, the
has been selected, each mode must be configured. submit button must be clicked at the bottom of the
Each mode is defined by the following selection: page. The ECM power must be cycled from off to on.

• Mode Number - (1-4) The status of the mode switch inputs can be
monitored on the status screen in the electronic
• Switch input 1 and 2 combinations to enable the service tool.
mode
Maintenance Indicator
• Enabled - For example, if only three modes are This feature is configured through the main
required then mode 4 would be set to “NO” . If the configuration screen in the electronic service tool.
switch combination was active for Mode 4, the
ECM would display a fault code.

• Rating number – This parameter allows any

available ratings in the flash file to be selected.
The specific rating information can be found in the
main configuration screen under “Ratings” .
• Rated Speed – This parameter is configurable
between defined limits in the ECM (for example –
1800 rpm to 2200 rpm).
• High Idle – This parameter is configurable
between 1800 rpm and 2800 rpm but also limited
to 112% of the programmed rated speed.
• Throttle Channel 1 Droop Value – This parameter
is configurable between 0-10%.
• Throttle Channel 2 Droop Value – This parameter
is configurable between 0-10%.

• TSC1 Droop Value – This parameter is

configurable between 0-10%.

• Governor Type – This parameter can be

configured to “All Speed” governing or “Min Max”
governing using the drop-down box.

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Illustration 105 g03422642

When this feature is installed, the number of

maintenance cycle hours can be set. The ECM will
then countdown these hours and flag an Event code
and send a J1939 message once the cycle interval
reaches 0.
This parameter can then be reset via the electronic
service tool or over the CAN data link after the
service has been completed.
The “PM1 Interval” is not applicable to this engine.

i07511910

Service Tool Error Identifiers

Service error identifiers are displayed when an

electronic service tool service test has failed. The
error identifiers help to explain the reason for the
service test failure. There could be cases where the
error identifier isolates the failed component. If
applicable, use the appropriate troubleshooting
procedure.
Table 220

Service Error Identifiers Description Troubleshooting

Only one service test may be active on a ma-
$0003 Another Service Test is Active
chine or engine at a time.

Another service test from a different ECM is

$0004 Service Test Active by Another ECM active. Either wait until the test is completed
or abort the test to proceed.

There is a communication issue between the

ECM and the electronic service tool. There is
$0005 Loss of Service Test Interlock too much data communicating across the data
link. Disconnect any other data collecting
tools.

$0006 Service Test Aborted by Tool/Monitor Abort by user. Restart the test if desired.

The throttle is depressed or faulty. If the appli-

$101A Incorrect Throttle Position cation contains a switched throttle, the switch
may be faulty.

$101B Shift Lever Not in Neutral Shift the transmission lever to NEUTRAL.

$101C Transmission Gear Incorrect Shift the power train to NEUTRAL.

$1018 Parking Brake Not Engaged Apply the parking brake.

(continued)

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(Table 220, contd)

Service Error Identifiers Description Troubleshooting

The left drive motor velocity is greater than 0.
$1109 Left Motor Rotation Direction Incorrect The motor could be faulted or have a loss of
communication on the datalink.
The right drive motor velocity is greater than
$110A Right Motor Rotation Direction Incorrect 0. The motor could be faulted or have a loss
of communication on the datalink.
Implements (or saws in forestry products) are
actively in operation. Hydraulics are not
locked out. Implement lockout solenoid is on
$1180 Machine is Not Idle “Hoist” and is not in float. AWD is installed and
the AWD system is in “Creep” mode. Steering
lockout is off. “OK To Elevate Speed” switch is
OFF.
The machine is moving. Stop the machine to
$1126 Ground Speed Too High
perform the service test.

$1012 Lever Not in Correct Position Shift lever to neutral.

$110C Brake Pedal Depressed Release the brake.

Wait for a DPF regeneration to complete or

$115C Regeneration is Active
abort the test.
Wiggle Test

$1011 Engine running Engine speed must be zero.

Fuel Rail Pressure Relief Valve Test

Resolve any active diagnostic codes. Refer to
$0002 Active Diagnostic Present
the appropriate troubleshooting procedure.

Fuel temperature must be above the threshold

$1161 Fuel Temperature Too High shown in the service tool and no active high
fuel temperature events .

Engine speed must be higher than or equal to

$10FB Engine Speed Too Low
low idle speed.

Engine speed must be lower than or equal to

$10FC Engine Speed Too High
rated speed.

Delivered fuel volume must be less than the

limit shown during the service tool test. An en-
gine speed from the application is preventing
$10CB Engine Load Too High the service test from taking control of the de-
sired engine speed. Check that the machine
is in a suitable operating mode before running
the service test.
Follow the troubleshooting procedure for the
$1162 Fuel Leakage Detected
fuel leakage event.

Refer to Troubleshooting, “Fuel Rail Pressure

$1101 Fuel Rail Pressure Too Low
Problem”.
The pressure relief valve may have opened
due to high rail pressure and is now regulating
the rail pressure. The rail pressure may be
$1100 Fuel Rail Pressure Too High
controlling incorrectly to be too high. Refer to
Troubleshooting, “Fuel Rail Pressure
Problem”.

(continued)

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 M0095947-10 419
Service

(Table 220, contd)

Service Error Identifiers Description Troubleshooting

Indicates that the rail pressure control is un-
$1118 Fuel Pressure Not Responding stable during the service test. Refer to Trou-
bleshooting, “Fuel Rail Pressure Problem”.

Fuel Rail Pressure Test

Resolve any active diagnostic codes. Refer to
the appropriate troubleshooting procedure.
Check that there are no electrical diagnostics
$0002 Active Diagnostic Present
on the fuel system-related sensors or actua-
tors and no injector faults relating to injector
trim codes.
Fuel temperature must be above the threshold
$1161 Fuel Temperature Too High shown in service tool and no high fuel temper-
ature events are active.
Engine speed must be higher than or equal to
$10FB Engine Speed Too Low
low idle speed.

Engine speed must be lower than or equal to

$10FC Engine Speed Too High
rated speed.

Delivered fuel volume must be less than the

limit shown during the service tool test. An en-
gine speed from the application is preventing
$10CB Engine Load Too High the service test from taking control of the de-
sired engine speed. Check that the machine
is in a suitable operating mode before running
the service test.
Contact the Dealer Solutions Network (DSN)
$1162 Fuel Leakage Detected if this fault occurs repeatedly when performing
this service test.
Refer to Troubleshooting, “Fuel Rail Pressure
$1101 Fuel Rail Pressure Too Low
Problem”.
The pressure relief valve may have opened
due to high rail pressure and is now regulating
the rail pressure. The rail pressure may be
$1100 Fuel Rail Pressure Too High
controlling incorrectly to be too high. Refer to
Troubleshooting, “Fuel Rail Pressure
Problem”.
Indicates that the rail pressure control is un-
stable during the service test. Contact the
$1118 Fuel Pressure Not Responding Dealer Solutions Network (DSN) if this fault
occurs repeatedly when running the service
test.
Aftertreatment Regeneration System Test

Resolve any active diagnostic codes. Refer to

$0002 Active Diagnostic Present
the appropriate troubleshooting procedure.

Allow engine to idle for 2 minutes and restart

$10D0 Engine Has Not Been Running Long Enough
the Aftertreatment Regeneration System Test.

Bring engine to idle and remove load and re-

start the Aftertreatment Regeneration System
$1164 Engine Speed / Load Incorrect Test. The test will try to take control of engine
speed to elevate idle to required position for
duration of test.

(continued)

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 420 M0095947-10
Service

(Table 220, contd)

Service Error Identifiers Description Troubleshooting

The system detects the DPF inlet temperature
not being high enough to allow successful
DPF desulfation.
$112C Particulate Filter Intake Temperature Too Low
Refer to Troubleshooting, “Diesel Particulate
Filter Intake Temperature Is Low”. Check for
exhaust leaks then restart the Aftertreatment
Regeneration System Test.

Bring engine to idle and remove load. The cur-

rent operating load could be too high to allow
Engine Exhaust Gas Recirculation Valve Not the NRS valve to close. Look for associated
$116F
Responding to Command NRS valve diagnostics. Run the Air System
Motor Valves Verification Test to check correct
operation of the NRS valve.

Air System Motor Valves Verification Test

Resolve any active diagnostic codes. Refer to

$0002 Active Diagnostic Present
the appropriate troubleshooting procedure.

For a 12 VDC system, the service test must

only be executed if the battery voltage is be-
tween 9 VDC and 16 VDC. For a 24 VDC sys-
$1050 Battery Voltage Too High tem, the service test must only be executed if
the battery voltage is between 18 VDC and 32
VDC. Correct the system voltage and restart
the Air System Motor Valves Verification Test.

For a 12 VDC system, the service test must

only be executed if the battery voltage is be-
tween 9 VDC and 16 VDC. For a 24 VDC sys-
$1070 Battery Voltage Too Low tem, the service test must only be executed if
the battery voltage is between 18 VDC and 32
VDC. Correct the system voltage and restart
the Air System Motor Valves Verification Test.

The test must be run with keyswitch ON only,

Stop Engine leaving ECM powered and re-
$1164 Engine Speed/Load Incorrect
start the Air System Motor Valves Verification
Test.
The test has verified that the valve is electri-
Engine Exhaust Gas Recirculation Valve Not cally OK, but the actuator is not responding to
$116F
Responding to Command the desired test profile. Contact the Dealer
Solutions Network (DSN) before proceeding.

The test has verified that the valve is electri-

Engine Throttle Actuator Not Responding to cally OK, but the actuator is not responding to
$1171
Command the desired test profile. Contact the Dealer
Solutions Network (DSN) before proceeding.

The test has verified that the valve is electri-

Engine Turbocharger Wastegate Actuator Not cally OK, but the actuator is not responding to
$1186
Responding to Command the desired test profile. Contact the Dealer
Solutions Network (DSN) before proceeding.

Aftertreatment System Functional Test

Resolve any active diagnostic codes. Refer to

$0002 Active Diagnostic Present
the appropriate troubleshooting procedure.

(continued)

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 M0095947-10 421
Service

(Table 220, contd)

Service Error Identifiers Description Troubleshooting

Not all conditions were met for the test to com-
$105F Service Test Timed Out plete. Restart the Aftertreatment System
Functional Test.
Bring engine to idle and remove load. Current
operating load is too high to allow the NRS
$10CB Engine Load Too High
valve to close. Restart the Aftertreatment Sys-
tem Functional Test.
Allow engine to Idle for 2 minutes and restart
$10D0 Engine Has Not Been Running Long Enough
the Aftertreatment System Functional test.

Lower the engine speed to idle. The test will

attempt to take speed control to put engine in
$10FB Engine RPM Too Low
acceptable speed range. Restart the After-
treatment System Functional Test.

Lower the engine speed to idle. The test will

attempt to take speed control to put engine in
$10FC Engine RPM Too High
acceptable speed range. Restart the After-
treatment System Functional Test.

The test request to take speed control was de-

$1121 Another Engine Speed Request Active
nied by the application.

The SCR system cannot dose due to the DPF

inlet temperature not being high enough to al-
$112C Particulate Filter Intake Temperature Too Low low DEF dosing to initiate. Check for exhaust
leaks and restart the Aftertreatment System
Functional Test.
HC dosing is active. Allow desulfation to com-
$115C Regeneration is Active plete and then restart the Aftertreatment Sys-
tem Functional Test.
Bring the engine to idle and remove load. The
Engine Exhaust Gas Recirculation Valve Not
$116F current operating load is too high to allow the
Responding to Command
NRS valve to close.
The SCR system NOx conversion is too low to
Aftertreatment SCR Catalyst Conversion Effi-
$11A8 perform the test. Refer to Troubleshooting,
ciency Too Low
“NOx Conversion is Low”.

Aftertreatment Diesel Exhaust Fluid Tempera- The temperature of the DEF is too low. Oper-
$11AA
ture Too Low ate the engine to raise the DEF Temperature.

The NOx sensors have not reached the cor-

Aftertreatment #1 NOx Level Sensors Not
$11B5 rect temperature to start reading the NOx
Ready
level.
The SCR system cannot dose due to the SCR
Aftertreatment #1 SCR Catalyst Intake Gas inlet temperature not being high enough to al-
$11B9
Temperature Too Low low DEF dosing to initiate. Restart the After-
treatment System Functional Test.

The DEF tank level is too low. Fill the DEF

Aftertreatment Diesel Exhaust Fluid Level Too
$11BB tank and restart the Aftertreatment System
Low
Functional Test.
The temperature of the exhaust system is not
high enough to perform the test. Operate the
$11C2 Aftertreatment SCR System in Warmup Mode engine to raise the exhaust temperatures. Re-
start the Aftertreatment System Functional
Test.

(continued)

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 422 M0095947-10
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(Table 220, contd)

Service Error Identifiers Description Troubleshooting

The SCR dosing system cannot prime. Refer
$11C3 Aftertreatment SCR System Not Able to Prime
to Troubleshooting, “DEF Pressure is Low”.

Manual Hydrocarbon Dosing Capability Test

Resolve any active diagnostic codes. Refer to

$0002 Active Diagnostic Present
the appropriate troubleshooting procedure.

Engine may not be running in the correct ther-

$0009 Service Test Aborted by ECM mal management mode. Contact the Dealer
Solutions Network (DSN) for further advice.

$1010 Engine Stopped (No Engine RPM) Start the engine. The test will then progress.

Allow engine to idle for 2 minutes and restart

$10D0 Engine Has Not Been Running Long Enough
the Manual HC Dosing Capability Test

DPF soot load is above an acceptable level

for safe HC dosing. If soot load events are ac-
$1155 Diesel Particulate Filter Soot Loading Too High
tive, refer to the appropriate troubleshooting
procedure.

The NRS valve must have closed to allow HC

dosing to start. Check for associated NRS
Engine Exhaust Gas Recirculation Valve Not
$116F valve diagnostic codes. Run the “Air System
Responding to Command
Motor Valves Verification Test” to check for
correct operation of the NRS valve.

The engine speed has changed significantly

during the test which can affect the service
$1108 Excessive Engine RPM Change
test assessment capability. Rerun the test
without changing engine speed.

The engine load has been changed signifi-

cantly during the test which can affect the
$10F5 Excessive Change in Engine Load
service test assessment capability. Rerun the
test without changing engine load.

The DOC may be sulfated. Run the “After-

treatment Recovery Procedure” . If this proce-
Aftertreatment Diesel Oxidation Catalyst Con-
$11CA dure continues to fail, the DOC may be aged
version Efficiency Too Low
so that not enough heat is being generated for
the amount of HC fuel being injected.

The DOC intake temperature is not reaching

Aftertreatment Diesel Oxidation Catalyst Intake the target required by the test. Look for
$11C0
Temperature Too Low causes of excessive heat loss between the
engine and the aftertreatment

The SCR system needs to dose a small

amount of DEF during HC dosing. The DEF
dosing is to protect the DEF injector tip from
getting damaged at high temperature. The
$11BA Aftertreatment SCR System Not Ready to Dose
SCR system is not working properly. Check
for associated SCR system diagnostic codes
and follow relevant troubleshooting
procedures.

The HC dosing procedure is generating the

correct heat rise. However, a significant
Aftertreatment #1 SCR Catalyst Intake Gas amount of this heat is being lost before the ex-
$11B9
Temperature Too Low haust gas reaches the SCR. Check for signs
of exhaust leaks in the CEM between the
DOC and the SCR.

(continued)

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 M0095947-10 423
Service

(Table 220, contd)

Service Error Identifiers Description Troubleshooting

“ High Pressure Fuel Pump Calibration””

Check that there are no electrical diagnostics

on fuel system sensors or actuators, no injec-
tor faults relating to injector trim codes. One of
the following sensor status is not OK:
Camshaft speed/timing
Crankshaft speed/timing
Coolant temperature
Fuel rail pressure
Fuel temperature.
$0002 Active Diagnostic Present There may be an electrical fault on an injector
or the HP fuel pump. An injector trim may not
be loaded or incorrect.
One of the following events is active:
Fuel leakage
Pressure relief valve activation
Rail pressure event
Battery supply diagnostic is active
Resolve any active diagnostic codes. Refer to
the appropriate troubleshooting procedure.

$10A7 Coolant Temperature Too Low Coolant temperature is less than the trip point

Coolant temperature is greater than the trip

$1072 Coolant Temperature Too High
point

Fuel temperature must be within limits dis-

$1160 Fuel Temperature Too Low
played during the test.

Fuel temperature must be within limits dis-

$1161 Fuel Temperature Too High
played during the test.

Engine speed is not stable. Ensure that there

is no cyclic loading from the application. Try
$1108 Excessive Engine RPM Change
running the test at a different engine speed or
increase the load on the engine.

Engine speed must be within limits displayed

$1074 Engine RPM Too Low
during the test.

Engine speed must be within limits displayed

$10FC Engine RPM Too High
during the test.

Fuel delivery must be within the limits dis-

$1107 Engine Load Too Low
played during the test.

Fuel delivery must be within the limits dis-

$10CB Engine Load Too High
played during the test.

Refer to Troubleshooting, “Fuel Rail Pressure

$1118 Fuel Pressure Not Responding
Problem”.
Changing the engine operating condition may
allow successful pump learn. A lower engine
$115F Engine Load Incorrect
speed and/or a lower load condition should be
used.
Likely loss of communication between the
ECM and the electronic service tool. Restart
$000A Calibration Failure
the electronic service tool and retry the cali-
bration test.

(continued)

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 424 M0095947-10
Service

(Table 220, contd)

Service Error Identifiers Description Troubleshooting

Likely loss of communication between the
ECM and the electronic service tool. Restart
$0003 Another Calibration is Active
the electronic service tool and retry the cali-
bration test.
Retry the “High Pressure Fuel Pump Calibra-
$105F Calibration Timed Out
tion” .
Aftertreatment Recovery Procedure

Resolve any active diagnostic codes. Refer to

$0002 Active Diagnostic Present
the appropriate troubleshooting procedure.

$1010 Engine Stopped (No Engine RPM) Start the engine. The test will then progress.

Allow engine to idle for 2 minutes and restart

$10D0 Engine Has Not Been Running Long Enough
the Aftertreatment Recovery Procedure.

Observed DPF soot load is above an accept-

able level for safe HC dosing and too high to
$1155 Diesel Particulate Filter Soot Loading Too High allow procedure to regenerate soot within the
DPF. Contact the Dealer Solutions Network
(DSN) for further advice.

The SCR system needs to dose a small

amount of DEF during HC dosing to protect
the DEF injector tip from damage at high tem-
$11BA Aftertreatment SCR System Not Ready to Dose peratures. The SCR system is not working
properly. Identify associated SCR system di-
agnostic codes and follow relevant trouble-
shooting procedures.

The system cannot dose due to the DPF Inlet

temperature not being high enough to allow
DEF dosing to initiate.
$112C Particulate Filter Intake Temperature Too Low Refer to Troubleshooting, “Diesel Particulate
Filter Intake temperature Is Low”. Check for
exhaust leaks and then restart the Aftertreat-
ment Recovery Procedure.

Lower the engine speed to idle. The test will

try to take speed control to put engine in ac-
$10FB Engine RPM Too Low
ceptable speed range. Restart the Aftertreat-
ment Recovery Procedure.

Lower the engine speed to idle. The test will

try to take speed control to put engine in ac-
$10FC Engine RPM Too High
ceptable speed range. Restart the Aftertreat-
ment Recovery Procedure.

The procedure is running in optimum condi-

tions for DPF soot regeneration with no issues
Diesel Particulate Filter Regeneration Rate Too with Soot Sensor measurement. However, ob-
$1173
Low served soot load is not reducing. Contact the
Dealer Solutions Network (DSN) for further
advice.
Bring engine to idle and remove load. The cur-
rent operating load may be too high to allow
Engine Exhaust Gas Recirculation Valve Not the NRS valve to close. Identify associated
$116F
Responding to Command NRS valve diagnostics. Run the “Air System
Motor Valves Verification Test” to check cor-
rect operation of the NRS valve.

(continued)

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 M0095947-10 425
Service

(Table 220, contd)

Service Error Identifiers Description Troubleshooting

The DOC intake temperature is lower than re-
Aftertreatment Diesel Oxidation Catalyst Intake quired for the test. Identify causes of exces-
$11C0
Temperature Too Low sive heat loss between the engine and the
aftertreatment.
The procedure has run in optimum engine
conditions but has been unable to recover the
$11C1 Aftertreatment Recovery Unsuccessful
Aftertreatment system. Contact the Dealer
Solutions Network (DSN) for further advice.

Although the procedure is generating the cor-

rect heat rise, some of this heat is being lost
Aftertreatment SCR Catalyst Intake Gas Tem-
$11B9 before the exhaust gas reaches the SCR.
perature Too Low
Check for evidence of exhaust leaks in the
CEM between the DOC and the SCR.

i06071165 Factory passwords are necessary to authorize

access to certain screens on the electronic service
Customer Passwords tool. Factory passwords are also used to access
specific configuration parameters in the Electronic
Control Module (ECM). If changes are made that
require factory passwords, the “Enter Factory
Customer passwords may be used to protect Passwords” dialog box will automatically be
customer parameters from being changed. The displayed. A factory password must be obtained
electronic service tool can be used to change certain before the change can be made.
parameters. There are some parameters that cannot
be changed and there are some applications that do Factory passwords may be required to perform each
not allow any changes to the programmable of the following functions in the electronic service
monitoring system. The passwords are programmed tool:
into the Electronic Control Module (ECM) with the ECM Replacement – When an ECM is replaced, the
electronic service tool. One password may be system configuration parameters must be
programmed or both passwords may be programmed into the new ECM. The new ECM will
programmed. If customer passwords are not allow specific parameters to be programmed once
programmed, customer parameters may be changed without the use of factory passwords. There may be
by anyone. parameters that require factory passwords on the
To obtain customer passwords, contact the owner of ECM that is being replaced. Factory passwords may
the machine. If the owner has forgotten the customer be required to configure these parameters on the
passwords, factory passwords are used to create new ECM.
temporary customer passwords. Temporary Rerate Engine Power – Changing the interlock code
customer passwords can be used to change the may be necessary. The interlock code is protected by
original customer passwords or any parameter that is factory passwords.
protected by a customer password. When the
electronic service tool is disconnected, a prompt will
request the restoration of the original customer Software Enabled Attachments – The application
passwords. If the original passwords are not may have special features that can be enabled with
restored, the passwords will be changed to the the electronic service tool. This customized software
temporary passwords. is available to provide enhanced operation for the
application. These features may also require the
i07527582
installation of additional hardware on the application.
A cost may be associated with these software
enabled attachments. Factory passwords are
Factory Passwords necessary to enable this software.

Customer passwords – Factory passwords are

Note: Factory passwords are provided only to required to restore customer passwords. Factory
Perkins authorized distributors. passwords are also required to reset customer
passwords.

Set Configuration parameters – Factory passwords

are required to modify specific configuration

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 426 M0095947-10
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parameters. If rechecking the passwords does not correct the

problem, change a customer parameter. Change the
parameter from the current value to another value
If factory passwords are needed to change a and then change the customer parameter back to the
parameter, the electronic service tool will request the original value. The sequence of events will change
password when the change is attempted. Newer the total tattletale. The new total tattletale will require
versions of the electronic service tool display a obtaining new factory passwords. Obtain and enter
padlock icon to indicate that a parameter requires a new factory passwords.
factory password for modification.
Clear engine events and certain diagnostic codes i07552220
– Some engine events require factory passwords to
clear the code from ECM memory. For example, Electronic Service Tool Does
factory passwords must be obtained to clear a code
that is related to an engine overspeed condition. Not Communicate
Clear these codes only when you are certain that the
fault has been corrected.

Probable Causes
i06071292
• Configuration of the communications adapter
ECM Will Not Accept Factory
• Electrical connectors
Passwords
• Communication adapter and/or cables

• Electrical power supply to the diagnostic

Probable Causes connector

• Incorrect information for the password request • Electronic service tool and related hardware

• Incorrect passwords • Electrical power supply to the Electronic Control

Module (ECM)
Recommended Actions Recommended Actions
Check the Information for the Password Note: The procedures have been listed in order of
Request probability. Complete the procedures in order.

The information for the password request must be

obtained from the Electronic Control Module (ECM)
that is being programmed. Do not use information
from an old ECM in order to program factory
passwords on a replacement ECM.
Verify that the information used for the password
request is identical to the information that is
displayed on the electronic service tool.
Engine Serial Number – The engine serial number
must be from the electronic service tool screen rather
than the engine information plate.
Reason Code – Use the reason code from the
factory password screen. Reason codes are
assigned for specific purposes and reason codes are
not interchangeable.

Cycle the keyswitch. Try to enter the passwords

again.

Incorrect Passwords
Verify that the correct passwords were entered.
Check each character in each password.

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 M0095947-10 427
Service

Table 221
Troubleshooting Test Steps Values Results

1. Configuration of the Communications Adapter Communications Result: The correct “Communications Interface Device” is
adapter not selected.
A. Access “Preferences” under the “Utilities” menu on the configuration
electronic service tool. Repair: Select the correct “Communications Interface De-
vice” .
B. Check for hardware that uses the same ports as the com-
munications adaptor. Result: The correct port is not selected for use by the
communication adapter.

Repair: Select the correct port for use by the communica-

tion adapter.
Note: The most commonly used port is “COM 1” .

Result: Other hardware is sharing the port with the com-

munications adaptor.

Repair: Exit or close the software programs for that

device.

Result: The communications adaptor is correctly

configured.

Proceed to Test Step 2.

2. Electrical Connectors Electrical Result: The connectors are not correctly installed.
connectors
A. Check for correct installation of the P1 and P2 ECM con- Repair: Repair or replace the connectors, as necessary.
nectors and of the connector for the electronic service tool.
Result: The connectors are OK.

Proceed to Test Step 3.

3. Communication Adapter and/or Cables Comms adaptor Result: The firmware or driver files are not the most cur-
and cables rent files.
A. Check that the firmware and driver files are the most current
files for the type of communication adapter that is being used. Repair: Update the firmware or driver files to the most
current files.
Verify that the correct cable is being used between the com-
munication adapter and the diagnostic connector. Result: The cable between the communication adapter
and the diagnostic connector is not correct.
B. Disconnect and then reconnect the cable that attaches the
communication adapter to the diagnostic connector. Repair: Replace the cable between the communication
adapter and the diagnostic connector with the correct
C. Check the operating system on the laptop computer. type.

Result: The laptop computer has a Windows operating

system.

Repair: Restart the laptop computer to eliminate the pos-

sibility of a conflict in the software.

Result: The adaptor and cables are OK.

Proceed to Test Step 4.

(continued)

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(Table 221, contd)

Troubleshooting Test Steps Values Results

4. Electrical Power Supply to the Diagnostic Connector Electrical power Result: Battery voltage is not present between terminals
A and B of the diagnostic connector.
A. Use a multimeter to check that battery voltage is present
between terminals A and B of the diagnostic connector. Repair: Investigate the cause and repair, as necessary.

Note: If the communication adapter is not receiving power, the Result: Battery voltage is present between terminals A
LED display on the communication adapter will be off. and B of the diagnostic connector.

Proceed to Test Step 5.

5. Electronic Service Tool and Related Hardware Hardware Result: The same fault occurs on a different engine.

A. Connect the electronic service tool to a different engine. Repair: Check the electronic service tool and the related
hardware for faults.
Note: This process eliminates the electronic service tool and
the related hardware as the fault. Result: The fault does not occur on a different engine.

Proceed to Test Step 6.

6. Electrical Power Supply to the Electronic Control Mod- Power to ECM Result: The power supply to the ECM is incorrect.
ule (ECM)
Repair: Investigate the cause and repair, as necessary.
A. Check the power supply to the ECM. Refer to Troubleshoot-
ing, “Electrical Power Supply - Test”. Result: The power supply to the ECM is OK.

Note: If the ECM is not receiving battery voltage, the ECM will Contact the Dealer Solution Network (DSN).
not communicate.

i07561799 3. Disconnect the suspect ECM. Temporarily connect

the test ECM to the engine. Do not mount the test
Test ECM Mode ECM on the engine.
4. Flash program the test ECM with the newest
software that is available.
“Test ECM Mode” is a feature in the software that can
be used to help troubleshoot an engine that may 5. Start the “Test ECM Mode” on the electronic
have a fault in the Electronic Control Module (ECM). service tool. Access the feature through the
This feature allows a standard ECM to be used as a
test ECM. This feature eliminates the need to stock a “Service” menu. The electronic service tool will
test ECM. display the status of the test ECM and the hours
that are remaining for the “Test ECM Mode” .
1. Search for the latest flash file for the engine.
Note: “Test ECM Mode” can only be activated if the
Note: If a newer software version is available for the engine serial number has not already been
engine, install the newest software on the suspect programmed during normal operation of the ECM. If
ECM. If the new software does not eliminate the fault, the engine serial number is programmed with the
continue with this procedure. ECM not in “Test ECM Mode” , the ECM can never be
used as a test ECM.
2. Use the “Copy Configuration” feature on the
electronic service tool to copy the parameters from 6. Use the “Copy Configuration” feature on the
the suspect ECM. electronic service tool to program the test ECM.
Note: If the “ECM Replacement” feature cannot be Note: If the “ECM Replacement” feature cannot be
used, record the programmed values into the used, program the test ECM with the values from
“Parameters Worksheet” . Also record the system Perkins Technical Marketing Information (PTMI).
configuration parameters.

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Service

7. Program the engine serial number into the test If the test ECM eliminates the fault, the engine can be
ECM. released while the “Test ECM Mode” is still active.

Note: The “Test ECM Mode” must be activated Once an ECM has been activated in the “Test ECM
Mode” , the ECM will stay in the “Test ECM Mode”
before the engine serial number is programmed into until the timer times out. Anytime prior to the “Test
the ECM. ECM Mode” timing out, the “Test ECM Mode” can be
reset to 24 hours.
8. Verify that the test ECM eliminates the fault.
If the ECM is used as a test ECM for more than one
When the “Test ECM Mode” is activated, an internal engine, reactivate the “Test ECM Mode” . The
timer sets a 24-hour clock. This clock will count down reactivation will reset the parameters to default
only while the ECM is powered and the keyswitch is values. Then use the “Copy Configuration” feature to
in the ON position. After the ECM has counted down program the parameters into the test ECM or
the 24-hour period, the ECM will exit the “Test ECM manually program the parameters to the correct
Mode” . The parameters and the engine serial values.
number will be set.
i07561439

ECM Software - Install

Table 222
Diagnostic Trouble Code for ECM Software

J1939 Code Code Description Comments

The flash file is for a different engine family or for a different engine
Personality Module : Erratic, Intermittent, or application.
631-2
Incorrect The engine will not start. Clearing this diagnostic code requires fac-
tory passwords. The personality module code must be reset to zero.

Flash Programming – A method of loading a flash a. Select the engine ECM under the “Detected
file into the Electronic Control Module (ECM) ECMs” .
The electronic service tool is used to install a flash b. Press the “Browse” button to select the part
file into the ECM. The flash programming transfers number of the flash file that will be programmed
the flash file from the PC to the ECM.
into the ECM.
Flash Programming a Flash File c. When the correct flash file is selected, press
1. Obtain the part number for the new flash file. the “Open” button.
d. Verify that the “File Values” match the
Note: If the part number for the flash file is not
available, use “PTMI” on the Perkins secured web application. If the “File Values” do not match the
site. application, search for the correct flash file.
e. When the correct flash file is selected, press
Note: The engine serial number must be available to
search for the part number of the flash file. the “Begin Flash” button.
f. The electronic service tool will indicate when
2. Connect the electronic service tool to the flash programming has been successfully
diagnostic connector. completed.
3. Turn the keyswitch to the ON position. Do not start 6. If the engine rating is being changed, factory
the engine. passwords must be obtained before the flash file
4. Select “WinFlash” from the “Utilities” menu on the will be accepted.
electronic service tool. 7. Access the “Configuration” screen under the
Note: If “WinFlash” will not communicate with the “Service” menu to determine the parameters that
ECM, refer to Troubleshooting, “Electronic Service require programming. Look under the “Tattletale”
Tool Does Not Communicate”. column. All the parameters should have a tattletale
of 1 or more. If a parameter has a tattletale of 0,
5. Flash program the flash file into the ECM. program that parameter.

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8. Start the engine and check for proper operation. Note: When a new ECM is not available, an ECM
Check that there are no active diagnostic codes. can be used from an engine that is not in service. The
ECM must have the same serial number suffix.
“ WinFlash”” Error Messages Ensure that the replacement ECM and the part
number for the flash file match the suspect ECM. Be
If any error messages are displayed during flash sure to record the parameters from the replacement
programming, click the “Cancel” button to stop the ECM. Use the “Copy Configuration ECM
process. Access the information about the “ECM Replacement” function in the electronic service tool.
Summary” under the “Information” menu. Ensure that
you are programming the correct flash file for your NOTICE
engine. If the flash file and engine application are not
matched, engine damage may result.
If a 630-2 diagnostic trouble code is displayed after
flash programming, a required parameter is missing.
Program the missing parameter. Perform the following procedure to replace the ECM.
1. Connect the electronic service tool to the
i07561787
diagnostic connector.
ECM - Replace 2. Use the “Copy Configuration ECM Replacement”
function from the electronic service tool. If the
“Copy Configuration” is successful, proceed to
Step 4. If the “Copy Configuration” failed, proceed
NOTICE to Step .
Keep all parts clean from contaminants.
Note: Record any Logged Faults and Events for your
Contaminants may cause rapid wear and shortened records.
component life.
3. Record the following parameters:
Engine ECM • Record all the parameters on the
The engine is equipped with an Electronic Control “Configuration” screen.
Module (ECM). The ECM contains no moving parts.
Follow the troubleshooting procedures in this manual • Record all the parameters on the “Throttle
to be sure that replacing the ECM will correct a fault. Configuration” screen.
Verify that the suspect ECM is the cause of the fault.
• Record all the parameters on the “Mode
Note: Ensure that the ECM is receiving power and Configuration” screen.
that the ECM is properly grounded before
replacement of the ECM is attempted. Refer to the • Record the serial numbers of the electronic unit
schematic diagram. injectors. The injector serial numbers are
shown on the “Injector Trim Calibration” screen.
A test ECM can be used to determine if the ECM on
the engine is faulty. Install a test ECM in place of the
suspect ECM. Install the flash file with the correct • Record the data from the “Current Totals”
part number into the test ECM. Program the screen.
parameters for the test ECM. The parameters must
match the parameters in the suspect ECM. Refer to Note: If the parameters cannot be read, the
the following test steps for details. If the test ECM parameters must be obtained elsewhere. Some
resolves the fault, reconnect the suspect ECM. Verify parameters are stamped on the engine information
that the fault returns. If the fault returns, replace the plate, but most parameters must be obtained from
ECM. PTMI data.
Note: If an ECM is used as a test ECM, select “Test 4. Remove power from the ECM.
ECM Mode” on the electronic service tool before the
engine serial number is entered. 5. Remove the ECM. Refer to Disassembly and
Assembly, “Electronic Control Module - Remove
Use the electronic service tool to read the and Install”.
parameters in the suspect ECM. Record the
parameters in the suspect ECM. Install the flash file 6. Install the replacement ECM. Refer to
into the new ECM. After the ECM is installed on the Disassembly and Assembly, “Electronic Control
engine, the parameters must be programmed into the
new ECM. Module - Remove and Install”.

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7. If the replacement ECM is used as a test ECM,

select “Test ECM Mode” on the electronic service
tool.
8. Download the flash file.
a. Connect the electronic service tool to the
diagnostic connector.
b. Select “WinFlash” from the “Utilities” menu of
the electronic service tool.
c. Select the downloaded flash file.
9. If necessary, use the electronic service tool to clear
the rating interlock. To clear the rating interlock,
enter the factory password when the electronic
service tool is first connected. Activating the Test
ECM mode will also clear the rating interlock.
10. Use the electronic service tool to program the
parameters. Perform the following procedure.
a. If the “Copy Configuration” procedure was
successful, use the “Copy Configuration, ECM
Replacement” function to load the configuration
file into the ECM.
Note: During the following procedure, factory
passwords may be required.

b. If the “Copy Configuration” procedure failed,

configure the parameters individually. The
parameters should match the parameters from
step 3.
11. Perform the “High Pressure Fuel Pump
Calibration” .
12. Check for logged diagnostic codes. Factory
passwords are required to clear logged events.

i08108999

DEF Pump - Replace

Table 223 lists the diagnostic codes for the Diesel

Exhaust Fluid (DEF) pump.
Table 223
Diagnostic Trouble Codes for the DEF Pump

J1939 Code Description Comments

Code
Aftertreatment 1 Diesel Exhaust Flu- The Electronic Control Module (ECM) detects an abnormal temperature signal from the
4337-8 id Doser 1 Temperature : Abnormal pump.
Frequency, Pulse Width, or Period The code is logged.

Aftertreatment #1 Diesel Exhaust

The ECM detects an abnormal motor speed signal from the pump.
4374-8 Fluid Pump Motor Speed : Abnormal
The code is logged.
Frequency, Pulse Width, or Period

Follow the troubleshooting procedure to identify the root cause of the problem.

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During the following procedure, refer to the electrical

schematic for the application.
Complete the procedure in the order in which the
steps are listed.
Table 224
Troubleshooting Test Steps Values Results

1. ECM Software Engine software Result: The latest engine software is not installed.

A. Verify that the latest engine software is installed in the ECM. Repair: Install the latest engine software. refer to Trouble-
shooting, ECM Software - Install for the correct
procedure.
Verify that the diagnostic code is no longer active. Return
the unit to service.

Result: The latest engine software is installed.

Proceed to Test Step 2.

2. Inspect the Harness Connector at the DEF Pump DEF pump Result: The DEF pump connector was free of DEF con-
connector tamination or corrosion.
A. Turn the keyswitch to the OFF position for 2 minutes. The
keyswitch must be OFF for 2 minutes to allow the DEF pump to Proceed to Test Step 3.
purge, reset the code, and reset the ECM.
Result: The DEF pump connector was not free of DEF
B. Disconnect the DEF pump electrical connector. contamination or corrosion.

C. Inspect the connector terminals for DEF contamination or Repair: Replace the wiring to the DEF pump. Proceed to
corrosion. Test Step 3.

(continued)

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(Table 224, contd)

Troubleshooting Test Steps Values Results

3. Replace the DEF Pump Leakage Result: The lines are not leaking.

A. Turn the keyswitch to the OFF position for 2 minutes. The Proceed to Test Step 4.
keyswitch must be OFF for 2 minutes to allow the DEF pump to
purge, reset the code, and reset the ECM. Result: The lines are leaking.

B. Replace the DEF pump. Refer to Disassembly and Assembly, Repair: Make the necessary repairs and repeat the “DEF
“Diesel Exhaust Fluid Pump - Remove and Install” for the correct Dosing System Verification Test” .
procedure.
Proceed to Test Step 4.
C. Establish communication between the electronic service tool
and the ECM.

D. Perform the “DEF Dosing System Verification Test” to pres-

surize and prime the system.

E. Visually inspect all DEF lines from the tank to the DEF injector
for leakage.

4. Perform an “ Aftertreatment System Functional Test”” Aftertreatment Result: The “Aftertreatment System Functional Test” was
System Function- successful and the code cleared.
A. Turn the keyswitch to the ON position. al Test
Return the unit to service.
B. Establish communication between the electronic service tool
and the engine ECM. Result: The “Aftertreatment System Functional Test” was
not successful and additional codes were logged.
C. Perform an “Aftertreatment System Functional Test” .
Troubleshoot the additional codes, Refer to Troubleshoot-
ing for the correct procedure.

If the fault is still present, contact the Dealer Solutions

Network (DSN).

i07988150 • Always use a 2900A033 Crimp Tool to service

Deutsch HD and DT connectors. Never solder the
Electrical Connectors - Inspect terminals onto the wires.
• Always use a 28170079 Removal Tool to remove
wedges from DT connectors. Never use a
Most electrical faults are caused by poor screwdriver to pry a wedge from a connector.
connections. The following procedure will help in
detecting faults with connectors and with wiring. If a • Always use a 2900A033 Crimp Tool to service
fault is found, correct the condition and verify that the AMP seal connectors.
fault is resolved.
• Refer to Troubleshooting, “Electrical Connectors”
Intermittent electrical faults are sometimes resolved to service the connectors for the Electronic Control
by disconnecting and reconnecting connectors. Module (ECM).
Check for diagnostic codes immediately before
disconnecting a connector. Also check for diagnostic • Always use a breakout harness for a voltmeter
codes after reconnecting the connector. If the status probe or a test light. Never break the insulation of
of a diagnostic code is changed due to disconnecting
and reconnecting a connector, there are several a wire to access a circuit for measurements.
possible reasons. The likely reasons are loose
• If a wire is cut, always install a new terminal for the
terminals, improperly crimped terminals, moisture,
corrosion, and inadequate mating of a connection. repair.

Follow these guidelines:

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The connection of any electrical equipment and

the disconnection of any electrical equipment
may cause an explosion hazard which may result
in injury or death. Do not connect any electrical
equipment or disconnect any electrical equip-
ment in an explosive atmosphere.

Illustration 106 g01131276

Diagram for the installation of a connector plug
(typical example)
(1) ECM connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug

Illustration 107 g01131019

Seal for a three-pin connector (typical example)

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Table 225
Troubleshooting Test Steps Values Results
1. Check Connectors for Moisture and Corrosion Harness, Result: A fault has been found with the harness or the
connectors, connectors.
A. Inspect all the harnesses. Ensure that the routing of the wiring and seals are
harness allows the wires to enter the face of each connector at a OK. Repair: Repair the connectors or the wiring, as required. En-
perpendicular angle. Otherwise, the wire will deform the seal bore. sure that all the seals are correctly installed. Ensure that the
This situation can create a path for the entrance of moisture. Verify connectors have been reattached.
that the seals for the wires are sealing correctly. If corrosion is evident on the pins, sockets or the connector,
use only denatured alcohol to remove the corrosion. Use a
B. Ensure that the sealing plugs are in place. If any of the plugs cotton swab or a soft brush to remove the corrosion.
are missing, replace the plug. Ensure that the plugs are inserted If moisture was found in the connectors, run the engine for
correctly into the connector. Refer to Illustration 106 . several minutes and check again for moisture. If moisture re-
appears, the moisture is wicking into the connector. Even if
C. Disconnect the suspect connector and inspect the connector the moisture entry path is repaired, replacement of the wires
seal. Ensure that the seal is in good condition. If necessary, re- may be necessary.
place the connector. Use the electronic service tool to clear all logged diagnostic
codes and then verify that the repair eliminates the fault.
D. Thoroughly inspect the connectors for evidence of moisture Result: The harness, connectors, and seals are in good
entry. condition.
Note: Some minor seal abrasion on connector seals is normal. Mi-
nor seal abrasion will not allow the entry of moisture. Proceed to Test Step 2.
If moisture or corrosion is evident in the connector, the source of
the moisture entry must be found and repaired. If the source of the
moisture entry is not repaired, the fault will recur. Simply drying
the connector will not rectify the fault. Check the following items
for the possible moisture entry path:
· Missing seals
· Incorrectly installed seals
· Nicks in exposed insulation
· Improperly mated connectors
Moisture can also travel to a connector inside a wire. If moisture is
found in a connector, thoroughly check the connector harness for
damage. Also check other connectors that share the harness for
moisture.
Note: The ECM is a sealed unit. If moisture is found in an ECM
connector, the ECM is not the source of the moisture. Do not re-
place the ECM.

E. Check the connectors for white deposits. White deposits may

indicate that the connector has been contaminated with Diesel Ex-
haust Fluid (DEF).
DEF may corrode the copper wire in the wiring harness.

2. Check the Wires for Damage to the Insulation The wiring is Result: There is damage to the harness.
OK
A. Carefully inspect each wire for signs of abrasion, nicks, and Repair: Replace the harness.
cuts. Use the electronic service tool to clear all logged diagnostic
Inspect the wires for the following conditions: codes and then verify that the repair eliminates the fault.
· Exposed insulation
· Rubbing of a wire against the engine Result: The wires are free of abrasion, nicks, and cuts and
· Rubbing of a wire against a sharp edge the harness is correctly clamped.

B. Check all the fasteners for the harness and the strain relief Proceed to Test Step 3.
components on the ECM to verify that the harness is correctly se-
cured. Also check all the fasteners to verify that the harness is not
compressed. Pull back the harness sleeves to check for a flat-
tened portion of wire. A fastener that has been overtightened flat-
tens the harness. This condition damages the wires that are inside
the harness.

(continued)

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(Table 225, contd)

Troubleshooting Test Steps Values Results
3. Inspect the Connector Terminals Terminals are Result: The terminals of the connector are damaged.
aligned and
Note: The ECM connectors cannot be repaired. If damage is undamaged Repair: Repair the terminals and/or replace the terminals,
found on an ECM connector, the harness must be replaced. as required.
Use the electronic service tool to clear all logged diagnostic
A. Visually inspect each terminal in the connector. Verify that the codes and then verify that the repair eliminates the fault.
terminals are not damaged. Verify that the terminals are correctly
aligned in the connector and verify that the terminals are correctly Result: The terminals are OK.
located in the connector.
Proceed to Test Step 4.

Illustration 108 g01802454

A typical example of the lock wedge.
(1) Lock wedge

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Table 226
Troubleshooting Test Steps Values Results
4. Perform a Pull Test on Each Wire Terminal Connection Pull test OK Result: A wire has been pulled from a terminal or a terminal
has been pulled from the connector in the 45 N (10 lb) pull
A. Ensure that the locking wedge for the connector is installed cor- test.
rectly. Terminals cannot be retained inside the connector if the
locking wedge is not installed correctly. Repair: Use the 2900A033 Crimp Tool to replace the termi-
nal. Replace damaged connectors, as required.
B. Perform the 45 N (10 lb) pull test on each wire. Each terminal Use the electronic service tool to clear all logged diagnostic
and each connector should easily withstand 45 N (10 lb) of ten- codes and then verify that the repair eliminates the fault.
sion and each wire should remain in the connector body. This test Result: All terminals pass the pull test.
checks whether the wire was correctly crimped in the terminal and
whether the terminal was correctly inserted into the connector. Proceed to Test Step 5.

5. Check the Locking Mechanism of the Connectors The connec- Result: The locking mechanism for the connector is dam-
tors are aged or missing.
A. Ensure that the connectors lock correctly. After locking the con- locked and
nectors, ensure that the two halves cannot be pulled apart. are not Repair: Repair the connector or replace the connector, as
damaged required.
B. Verify that the latch tab of the connector is correctly latched. Al- Use the electronic service tool to clear all logged diagnostic
so verify that the latch tab of the connector returns to the locked codes and then verify that the repair eliminates the fault.
position.
Result: The connectors are in good condition.

Proceed to Test Step 6.

6. Perform the “ Wiggle Test”” on the Electronic Service Tool Intermittent Result: No intermittent faults were found.
faults were
A. Select the “Wiggle Test” from the diagnostic tests on the elec- indicated. If directed here from another procedure, return to the proce-
tronic service tool. dure and continue testing. If this test confirms that the fault
has been eliminated, return the engine to service.
B. Choose the appropriate group of parameters to monitor.
Result: At least one intermittent fault was indicated.
C. Press the “Start” button. Wiggle the wiring harness to repro-
duce intermittent faults. Repair: Repair the harness or the connector.
If an intermittent fault exists, the status will be highlighted and an
audible beep will be heard. Use the electronic service tool to clear all logged diagnostic
codes and then verify that the repair eliminates the fault.

i07561938

Injector Code - Calibrate

Injector codes are codes that are 30 hexadecimal

characters in length that are supplied with each
injector. The code is on a plate on the top of the
injector and a card is also included in the packaging
for the injector. The code is used by the Electronic
Control Module (ECM) to balance the performance of
the injectors.

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• Electronic unit injectors are exchanged between

cylinders.
If the ECM is replaced, the injector codes are
normally transferred to the new ECM as part of the
“Copy Configuration” procedure. If the “Copy
Configuration” procedure fails, the injector codes
must be loaded manually.
Installing Injector Codes

Note: The injector code is on the top of the electronic

unit injector.

1. Record the injector code for each electronic unit

injector.
2. Connect the electronic service tool to the
diagnostic connector. Refer to Troubleshooting,
“Electronic Service Tools”.
3. Turn the keyswitch to the ON position.

Illustration 109 g06360333 4. Select the following menu options on the electronic
Label with the injector code service tool:

• Service

• Calibrations

• Injector Codes Calibration

5. Select the appropriate cylinder.

6. Click the “Change” button.
7. Input the applicable injector code that was
recorded in Test Step 1.
8. Click the “OK” button.
The injector code is loaded into the ECM.

Illustration 110 g06360350

9. Repeat the procedure for each cylinder, as
required.
Sequence for recording the injector code
Exchanging Electronic Unit Injectors
The electronic service tool is used to load the injector
codes into the ECM.
The injector codes must be loaded into the ECM if
any of the following conditions occur:
• An electronic unit injector is replaced.

• The ECM is replaced.

• A -2 diagnostic code is active for one or more of
the injectors

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Exchanging electronic unit injectors can help must also be exchanged. Press the “Exchange”
determine if a combustion problem is in the electronic button at the bottom of the “Injector Trim Calibration”
unit injector or in the cylinder. If two electronic unit screen on the electronic service tool. Select the two
injectors that are currently installed in the engine are electronic unit injectors that will be exchanged and
exchanged between cylinders, the injector codes press the “OK” button.
i07566733

SCR Inducement Emergency

Override

Table 227
Diagnostic Trouble Codes for SCR Inducement Emergency Override

J1939 Code Code Description Comments

SCR Inducement Override Renewal This code indicates that the Inducement Override has been activated.
7343–31
Required The code is logged.

Follow the troubleshooting procedure to identify the root cause of the fault.

When an emergency situation occurs, initial

activation of the override is allowed without input
from Caterpillar ™. Prior to activation, the operator will
be notified of the following on display :
“EMERGENCY USE ONLY. SEE OWNERS
MANUAL. PENALTIES APPLY FOR MISUSE” .
Upon activation, the check engine, and action lamps
will also illuminate to alert the operator that the
override is active. A code will also become active
indicating that the engine emission operator
inducement emergency override is active. The code
will remain active until the override is reset. The
override must be paused by the operator if the
emergency ends before the 120 hours of override
operation has expired. While paused, the equipment
will be subject to inducements (derates). The
override may be reactivated if an emergency
situation returns. After 120 hours of override use the
override will expire, and the equipment will be subject
to inducements. Upon activation, the check engine
and action lamps will continue to be illuminated until
the override is reset. If the override has expired, the
dealer will need to reset the override to use the
override again. The code indicating that the engine
emission operator inducement emergency override is
active, will be cleared when the override is reset.
Resetting the override is the only way to clear the
code.
The override needs to be reset by an authorized
dealer or distributor through the electronic service
tool whenever the override has expired. The override
cannot be used again until the override is reset. The
warning lamp will continue to be illuminated until the
override is reset. The override may be reset at any
point after the initial activation.

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Illustration 111 g06241919

Illustration 112 g06241920

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Table 228
Troubleshooting Test Steps Values Results

1. Reset the Operator Inducement Emergency Override Reset Result: The Emergency Inducement Operator Override
Reset was performed.
A. Connect the electronic service tool to the diagnostic
connector. Return the unit to service.

B. Under the “Service Tab” , navigate to “Operator Inducement

Emergency Override Timer Reset” .

C. Click the “Reset” button at the bottom of the screen.

i08139405

Turbocharger - Clean

Diagnostic Codes
Table 229
Diagnostic Codes for Turbocharger - Clean

J1939 Code Code Description Comments

Engine Turbocharger #1 Efficiency: The ECM has determined that the turbocharger efficiency loss has exceeded an inter-
8631–17
Low – Least Severe mediate threshold. Clean the turbocharger at the next service interval.

The ECM has determined that the turbocharger efficiency loss has exceeded a severe
Engine Turbocharger #1 Efficiency:
8631–18 threshold. Clean the turbocharger immediately to prevent loss of engine performance
Low – Moderate Severity
and turbocharger damage.

Perform the following procedure if one of the

diagnostic codes listed in Table 229 is active.

Note: Only perform this procedure if the engine is

equipped with a closed circuit breather. If any of the
diagnostic codes listed above are active on an
engine equipped with an open circuit breather, install
the latest engine software. Refer to Troubleshooting,
ECM Software - Install for the correct procedure.

Disassembly Procedure
1. Remove the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Remove” for the
correct procedure.

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Illustration 114 g06521480

Typical example

6. Use a soft faced tool to disengage the

turbocharger compressor housing (2) from
turbocharger back plate (7) in the direction
indicated in Illustration 114 .

Illustration 113 g06521439

Typical example

2. Place turbocharger (1) in a suitable support.

3. Place temporary marks in Positions (X) on the
turbocharger compressor housing (2) and
turbocharger back plate (7) for installation
purposes.
4. Remove circlip (4) from poppet arm (5) . Remove
actuator rod (6) from the poppet arm.
5. Loosen bolts (3) by one turn.
Note: Do not use mechanically driven tooling, use
hand tools only.

Illustration 115 g06521638

Typical example

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7. Support turbocharger compressor housing (2).

Remove bolts (3) and remove the turbocharger
compressor housing.
Note: Do not rotate the turbocharger compressor
housing as this will damage the anti-rotation pin (9).

Note: Remove the turbocharger compressor housing

axially to avoid damaging the turbocharger
compressor wheel blades.

8. Remove O-ring seal (8) (not shown) from

turbocharger back plate (7). Discard the O-ring
seal.

Cleaning Procedure
Table 230
Required Tools

Tool Part Part Description Qty

Number
A - Loctite Electronic and 1 Illustration 116 g06521519
Part Cleaner Typical example

NOTICE NOTICE
Care must be taken to ensure that fluids are con- Do not attempt using any brush or other methods for
tained during performance of inspection, mainte- cleaning except the one specified in this procedure.
nance, testing, adjusting, and repair of the product.
Be prepared to collect fluid with suitable containers Do not attempt to wipe the components with any cloth
before opening any component or disassembling any or towel as any fibers or parts of cloth will end up in
components containing fluids. other engine components.

Dispose of all fluids according to local regulations Do not spray cleaning agent directly behind compres-
and mandates. sor wheel.

1. Using Tooling (A) from a distance of 150 mm

NOTICE
Keep all parts clean from contaminants. (6 inch). Thoroughly clean the turbocharger
backplate (7) and turbocharger compressor wheel
Contaminants may cause rapid wear and shortened blades (10).
component life.
Note: Ensure that there is no oil residue left on the
components.

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Illustration 117 g06521533

Typical example

2. Using Tooling (A) to thoroughly clean turbocharger

compressor housing (2). Ensure that there is no oil
residue in the volute (13) or inlet recirculation slot
(12).
Note: Ensure that there is no oil residue or cleaning
fluid left on and in the component. Rotate the
component in varying directions to ensure that
excess cleaning fluid and debris are removed.
Note: After, cleaning is complete allow 10 minutes for
the cleaning agent to evaporate before starting the
reassembly process.

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Assembly Procedure

Illustration 119 g06521638

Typical example

3. Position turbocharger compressor housing (2) onto

turbocharger back plate (7). Ensure that O-ring
seal (8) (not shown) is not dislodged during the
assembly process. Ensure the temporary marks in
Position (X) and anti-rotation pin (9) are aligned.
Illustration 118 g06521439
Install new bolts (3), tighten the bolts finger tight.
Typical example
Note: Do not rotate the turbocharger compressor
1. Place turbocharger (1) in a suitable support. housing as this will damage the anti-rotation pin.
2. Install new O-ring seal (8) (not shown) onto Note: Install the turbocharger compressor housing
turbocharger back plate (7). axially to avoid damaging the turbocharger
compressor wheel blades.

4. Tighten bolts (3) to a torque of 7 N·m (62 lb in).

5. Position the actuator rod (6) onto the poppet arm
(5). Install circlip (4) to the poppet arm.
6. Install the turbocharger. Refer to Disassembly and
Assembly, “Turbocharger - Install” for the correct
procedure.
7. If a new turbocharger wastegate actuator is
installed, use the electronic service tool to perform
the “Turbocharger Wastegate Actuator
Replacement Reset” . Refer to Troubleshooting,
“Service Tool Features” for more information.

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8. Use the electronic service tool to perform the

“Engine Turbocharger #1 Estimated Efficiency
Loss Reset” . Refer to Troubleshooting, “Service
Tool Features” for more information.
9. Use the electronic service tool to perform the “Air
Systems Motor Valve Verification Test” . Refer to
Troubleshooting, “Service Tool Features” for more
information.

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 M0095947-10 447
Index Section

Index
A DEF Tank Temperature Is High.............................73
DEF Temperature Is Low .....................................75
Acceleration Is Poor or Throttle Response Is Diagnostic Capabilities ........................................20
Poor .................................................................36 Diagnostic Codes.............................................20
Probable Causes .............................................36 Diagnostic Trouble Codes....................................23
Recommended Actions ....................................36 Diagnostic Trouble Codes in J1939 Order..........23
Alternator Problem (Charging Problem and/or Diesel Oxidation Catalyst Has Incorrect Inlet
Noisy Operation) ...............................................41 Temperature .....................................................79
Probable Causes .............................................41 Diesel Oxidation Catalyst Has Low Conversion
Recommended Actions ....................................41 Efficiency ..........................................................81
Diesel Particulate Filter Collects Excessive Soot....82
B Diesel Particulate Filter Has Low Inlet Pressure.....86
Diesel Particulate Filter Regeneration ...................18
Battery Problem ..................................................43 Regeneration...................................................18
Probable Causes .............................................43 Selective Catalyst Reduction (SCR) ..................19
Recommended Actions ....................................43 Diesel Particulate Filter Temperature Is Low ..........86

C E
CAN Data Link - Test ......................................... 206 ECM - Replace ................................................. 430
Circuit Tests...................................................... 206 Engine ECM .................................................. 430
Clean Emissions Module Has High Oxygen ECM Software - Install ....................................... 429
Level ................................................................44 Flash Programming a Flash File...................... 429
Component Location ...........................................10 ECM Will Not Accept Factory Passwords ............ 426
Electronic Control Circuit Diagram.....................10 Probable Causes ........................................... 426
Sensor Locations .............................................13 Recommended Actions .................................. 426
Configuration Parameters ....................................21 Electrical Connectors - Inspect ........................... 433
Check Programmable Parameters (630–2) ........22 Electrical Power Supply - Test ............................ 253
Coolant Contains Oil ...........................................45 Electronic Service Tool Does Not Communicate .. 426
Probable Causes .............................................45 Probable Causes ........................................... 426
Recommended Actions ....................................45 Recommended Actions .................................. 426
Coolant Diverter - Test ....................................... 209 Electronic System Overview...................................8
Coolant Level Is Low ...........................................47 Engine Cranks but Does Not Start ........................91
Probable Causes .............................................48 Probable Causes .............................................91
Recommended Actions ....................................48 Recommended Actions ....................................92
Coolant Temperature Is High................................48 Engine Does Not Crank .......................................98
Probable Causes .............................................49 Engine Has Early Wear...................................... 100
Recommended Actions ....................................49 Probable Causes ........................................... 100
Coolant Temperature Is Low ................................53 Recommended Actions .................................. 100
Probable Causes .............................................53 Engine Has Mechanical Noise (Knock) ............... 102
Recommended Actions ....................................53 Probable Causes ........................................... 102
Cooling Fan Control - Test ................................. 214 Recommended Actions .................................. 102
Cooling Fan Speed - Test................................... 218 Engine Misfires, Runs Rough or Is Unstable........ 106
Customer Passwords ........................................ 425 Probable Causes ........................................... 106
Cylinder Is Noisy .................................................54 Recommended Actions .................................. 106
Probable Causes .............................................54 Engine Monitoring System ...................................19
Recommended Actions ....................................54 Viewing or Changing the Settings of the Monitoring
System..........................................................19
Engine Overcrank Occurrence ........................... 111
D Probable Causes ........................................... 111
Data Link Configuration Status - Test .................. 220 Recommended Actions .................................. 111
DEF Does Not Purge ...........................................57 Engine Overspeeds........................................... 114
DEF Injector - Test............................................. 222 Probable Causes ........................................... 114
DEF Line Heater - Test ...................................... 227 Recommended Actions .................................. 114
DEF Module Does Not Respond...........................58 Engine Shutdown Occurs Intermittently............... 117
DEF Pressure Is High ..........................................62 Probable Causes ........................................... 117
DEF Pressure Is Low...........................................64 Recommended Actions .................................. 117
DEF Pump - Replace......................................... 431 Engine Shutdown While Idling ............................ 119
DEF Pump Motor - Test ..................................... 232 Probable Causes ........................................... 119
DEF Pump Pressure Sensor - Test ..................... 237 Recommended Actions .................................. 120
DEF Return Valve - Test..................................... 242 Engine Speed - Test .......................................... 255
DEF Tank Level Is Low ........................................70 Probable Causes ........................................... 256
DEF Tank Sensor - Test ..................................... 249 Recommended Actions .................................. 256
Engine Stalls at Low RPM.................................. 120

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 448 M0095947-10
Index Section

Probable Causes ........................................... 120 Intake Manifold Air Pressure Is Low .................... 159
Recommended Actions .................................. 120 Probable Causes ........................................... 159
Engine Top Speed Is Not Obtained ..................... 123 Recommended Actions .................................. 159
Probable Causes ........................................... 123 Intake Manifold Air Temperature Is High.............. 162
Recommended Actions .................................. 123 Probable Causes ........................................... 162
Engine Vibration Is Excessive ............................ 128 Recommended Actions .................................. 162
Probable Causes ........................................... 128 Introduction ..........................................................5
Recommended Actions .................................. 128
Ether Actuation Occurrence Is Excessive ..............87
Probable Causes .............................................88 M
Recommended Actions ....................................88 Mode Selection - Test ........................................ 295
Ether Starting Aid - Test ..................................... 258 Motorized Valve - Test ....................................... 297
Exhaust Has Excessive Black Smoke ................. 130
Probable Causes ........................................... 130
Recommended Actions .................................. 130 N
Exhaust Has Excessive White Smoke................. 133
Probable Causes ........................................... 133 NOx Conversion Is Low ..................................... 164
Recommended Actions .................................. 133 NOx Sensor Supply - Test .................................. 304
Exhaust System Contains Coolant...................... 137 NRS Exhaust Gas Temperature Is High .............. 171
Probable Causes ........................................... 137 Probable Causes ........................................... 172
Recommended Actions .................................. 138 Recommended Actions .................................. 172
Exhaust System Contains Oil ............................. 139 NRS Mass Flow Rate Problem ........................... 173
Probable Causes ........................................... 139 Probable Causes ........................................... 175
Exhaust Temperature Is High ............................. 141 Recommended Actions .................................. 175
Probable Causes ........................................... 141
O
F Oil Consumption Is Excessive ............................ 178
Factory Passwords............................................ 425 Probable Causes ........................................... 178
Fuel Consumption Is Excessive.......................... 144 Recommended Actions .................................. 178
Probable Causes ........................................... 144 Oil Contains Coolant ......................................... 180
Recommended Actions .................................. 144 Probable Causes ........................................... 180
Fuel Contains Water.......................................... 148 Recommended Actions .................................. 180
Recommended Actions .................................. 148 Oil Contains Fuel .............................................. 182
Fuel Control - Test ............................................. 262 Measuring Fuel Dilution.................................. 182
Fuel Rail Pressure Problem ............................... 149 Probable Causes ........................................... 182
Probable Causes ........................................... 150 Recommended Actions .................................. 182
Recommended Actions .................................. 150 Oil Level Is Low................................................. 183
Fuel Temperature Is High................................... 153 Probable Causes ........................................... 184
Probable causes............................................ 153 Recommended Actions .................................. 184
Fuel Transfer Pump - Test.................................. 266 Oil Pressure Is Low ........................................... 185
Probable Causes ........................................... 186
Recommended Actions .................................. 186
G
General Information ..............................................5 P
Application Interface ..........................................5
Clean Emissions Module (CEM)..........................5 Power Is Intermittently Low or Power Cutout Is
Electronic Control System ..................................5 Intermittent...................................................... 189
Fault Detection and Reporting.............................6 Probable Causes ........................................... 189
Important Safety Information...............................5 Recommended Actions .................................. 189
Overview...........................................................5
Troubleshooting.................................................6
Glow Plug Starting Aid - Test .............................. 271 R
Relay - Test (SCR Main Relay) ........................... 308
Relay - Test (Start Relay) ................................... 306
I
Idle Validation - Test .......................................... 276
Important Safety Information ..................................2 S
Indicator Lamp - Test ......................................... 283 SCR Catalyst Has Incorrect Inlet Temperature..... 192
Injector Code - Calibrate .................................... 437 Probable causes............................................ 192
Injector Data Incorrect - Test .............................. 286 SCR Inducement Emergency Override ............... 439
Injector Solenoid - Test ...................................... 288 SCR Warning System Problem........................... 194
Inlet Air Is Restricted ......................................... 155 Associated Codes.......................................... 195
Intake Manifold Air Pressure Is High ................... 156 Operator Level Inducement ............................ 194
Probable Causes ........................................... 156 World-Wide DEF Level Warnings .................... 202
Recommended Actions .................................. 157 World-Wide Reduce Time Setting ................... 201

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 M0095947-10 449
Index Section

World-Wide Reduced Performance Setting ...... 199 Welding Precaution ...............................................6

Sensor (Data Link Type) - Test ........................... 314
Sensor Calibration Required - Test ..................... 312
Sensor Signal (Analog, Active) - Test .................. 318
Sensor Signal (Analog, Passive) - Test ............... 325
Sensor Supply - Test ......................................... 332
Service............................................................. 371
Service Tool Error Identifiers .............................. 417
Service Tool Features........................................ 371
Active Diagnostic Codes................................. 371
Active Event Codes........................................ 372
Aftertreatment History .................................... 396
Calibrations ................................................... 390
Diagnostic Tests ............................................ 372
Dyno Mode.................................................... 391
Engine Operating Mode Configuration ............. 415
Histogram Screens ........................................ 402
Logged Diagnostic Codes............................... 371
Logged Event Codes...................................... 372
Maintenance Indicator .................................... 416
Override Parameters...................................... 371
Service Procedures........................................ 395
Service Tool Error Identifiers ........................... 396
System Communication Status ....................... 410
System Troubleshooting Settings .................... 371
Throttle Mode Configuration ........................... 410
Speed Control (Analog) - Test ............................ 334
Speed Control (PWM) - Test............................... 340
Speed/Timing - Test .......................................... 346
Switch Circuits - Test (Air Filter Restriction
Switch) ........................................................... 353
Switch Circuits - Test (Engine Oil Pressure
Switch) ........................................................... 349
Switch Circuits - Test (Multiposition Throttle
Switch) ........................................................... 356
Symptom Troubleshooting ...................................36
System Overview ..................................................8
Other ECM Functions for Performance ................8
Passwords ........................................................9
Programmable Parameters.................................9
System Operation ..............................................8

T
Table of Contents ..................................................3
Test ECM Mode ................................................ 428
Transmission Oil Temperature Is High................. 203
Probable Causes ........................................... 203
Recommended Actions .................................. 203
Troubleshooting Section ........................................5
Turbocharger - Clean ........................................ 441
Assembly Procedure ...................................... 445
Cleaning Procedure ....................................... 443
Diagnostic Codes........................................... 441
Disassembly Procedure ................................. 441

V
Valve Lash Is Excessive .................................... 204
Probable Causes ........................................... 204
Recommended Actions .................................. 204
Valve Position - Test .......................................... 358

W
Water in Fuel - Test ........................................... 365

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 M0095947
©2021 Perkins Engines Company Limited
All Rights Reserved

450 March 2021

This document has been printed from SPI2. NOT FOR RESALE