PERKINS 2206F 2506F 2806F Fallas Soluciones 2017 PDF

M0070030-01 (en-us)
January 2017
Troubleshooting
2206F-E13TA, 2506F-E15TA and
2806F-E18TA Industrial Engines
P84 (Engine)
PP5 (Engine)
PP4 (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 properly.
Improper 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. 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 the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
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.
M0070030-01 3
Table of Contents
Table of Contents Diesel Particulate Filter Has High Ash Load ........ 206
Diesel Particulate Filter Has High Inlet Pressure .. 207
Diesel Particulate Filter Has Low Inlet Pressure... 209
Troubleshooting Section Diesel Particulate Filter Temperature Is High ....... 210
Diesel Particulate Filter Temperature Is Low ........ 213
Engine Cranks but Does Not Start ...................... 216
Introduction Engine Does Not Crank ..................................... 219
General Information ..............................................5 Engine Has Early Wear...................................... 220
Welding Precaution ...............................................6 Engine Has Mechanical Noise (Knock) ............... 222
Electronic Service Tools.........................................7 Engine Misfires, Runs Rough or Is Unstable........ 225
Engine Overcrank Occurrence ........................... 227
Electronic System Overview Engine Overspeeds........................................... 230
System Overview ................................................10 Engine Shutdown Occurrence............................ 231
Component Location ........................................... 11 Engine Shutdown Occurs Intermittently .............. 234
Diesel Particulate Filter Regeneration ...................29 Engine Shutdown While Idling ............................ 237
Engine Monitoring System ...................................30 Engine Stalls at Low RPM.................................. 237
Diagnostic Capabilities ........................................31 Engine Top Speed Is Not Obtained ..................... 240
Electrical Connectors ..........................................32 Engine Vibration Is Excessive ............................ 243
Exhaust Has Excessive Black Smoke ................. 244
Configuration Parameters Exhaust Has Excessive White Smoke................. 246
Configuration Parameters ....................................38 Exhaust System Contains Coolant...................... 250
Exhaust System Contains Fuel........................... 251
Diagnostic Trouble Codes Exhaust System Contains Oil ............................. 254
Diagnostic Trouble Codes....................................41 Exhaust Temperature Is High ............................. 256
Fuel Consumption Is Excessive.......................... 260
Event Codes Fuel Filter Is Restricted ...................................... 262
Event Codes ......................................................72 Fuel Pressure Is High ........................................ 263
Fuel Pressure Is Low ......................................... 269
Fuel System Water Separator Has Water ............ 273
Symptom Troubleshooting Fuel Temperature Is High................................... 275
Acceleration Is Poor or Throttle Response Is Poor .89 Idle Speed Is High ............................................. 279
Alternator Problem ..............................................91 Indicator Lamp Problem..................................... 280
ARD Combustion Supply Air Pressure Is Low........93 Inlet Air Is Restricted ......................................... 281
ARD Failed to Ignite ............................................97 Intake Manifold Air Pressure Is Low .................... 282
ARD Fuel Pressure Is High ................................ 106 Intake Manifold Air Temperature Is High.............. 285
ARD Fuel Pressure Is Low ................................. 115 NOx Conversion Is Low ..................................... 288
ARD Is Disabled................................................ 126 NRS Exhaust Gas Temperature Is High .............. 293
ARD Loss of Combustion................................... 130 Oil Consumption Is Excessive ............................ 297
ARD Temperature Is Low ................................... 137 Oil Contains Coolant ......................................... 299
Battery Problem ................................................ 142 Oil Contains Fuel .............................................. 302
Clean Emissions Module Has High Oxygen Level 143 Oil Pressure Is Low ........................................... 303
Coolant Contains Fuel ....................................... 144 Oil Temperature Is High ..................................... 307
Coolant Contains Oil ......................................... 145 Power Is Intermittently Low or Power Cutout Is
Coolant Level Is Low ......................................... 148 Intermittent...................................................... 309
Coolant Pressure Is Low .................................... 150 SCR Warning System Problem........................... 312
Coolant Temperature Is High.............................. 154 Valve Lash Is Excessive .................................... 316
Coolant Temperature Is Low .............................. 157 Valve Rotator or Spring Lock Is Free................... 318
Cooling Fan Is Always ON ................................. 159
Crankcase Fumes Disposal Tube Has Oil
Draining.......................................................... 160 Circuit Tests
Crankcase Pressure Is High............................... 161 Air Shutoff - Test................................................ 320
Crankcase Pressure Is Low ............................... 164 Aftertreatment Identification Module - Test........... 325
Cylinder Is Noisy ............................................... 166 ARD Combustion Air - Test ................................ 330
DEF Control Module Temperature Is High ........... 168 ARD Fuel Supply - Test...................................... 337
DEF Does Not Purge ......................................... 170 ARD Ignition - Test ............................................ 342
DEF Module Does Not Respond......................... 171 ARD Nozzle Heater - Test .................................. 347
DEF Pressure Is High ........................................ 174 Coolant Level - Test........................................... 356
DEF Pressure Is Low......................................... 177 Cooling Fan Control - Test ................................. 359
DEF Tank Level Is Low ...................................... 185 Cooling Fan Reversing - Test ............................. 362
DEF Tank Temperature Is High........................... 188 Cooling Fan Speed - Test................................... 364
DEF Temperature Is Low ................................... 192 Data Link - Test ................................................. 367
Desulfation Is Frequent...................................... 196 Data Link Configuration Status - Test .................. 376
Diesel Particulate Filter Collects Excessive Soot.. 200 DEF Control Module Power - Test....................... 379
Diesel Particulate Filter Has Changed Regeneration DEF Line Heater - Test ...................................... 383
Interval ........................................................... 203 DEF Pump Motor - Test ..................................... 391
DEF Pump Pressure Sensor - Test ..................... 395
4 M0070030-01
Table of Contents
DEF Pump Sensor Supply - Test ........................ 397

DEF Return Valve - Test..................................... 400
DEF Tank Sensor - Test ..................................... 403
Electrical Power Supply - Test ............................ 406
Ether Starting Aid - Test ..................................... 409
Exhaust Balance Valve - Test ............................. 413
Injector Solenoid - Test ...................................... 420
NOx Reduction System (NRS) - Test .................. 427
NOx Sensor - Test ............................................. 435
Retarder - Test .................................................. 437
SCR Catalyst Inlet Temperature Sensor - Test ..... 444
Sensor Calibration Required - Test ..................... 447
Sensor (Data Link Type) - Test ........................... 451
Sensor Signal (Analog, Active) - Test .................. 454
Sensor Signal (Analog, Passive) - Test ............... 468
Sensor Supply - Test ......................................... 474
Shutdown (Ground Level) - Test ......................... 477
Solenoid Valve - Test ........................................ 480
Speed Control - Test.......................................... 489
Speed/Timing - Test .......................................... 492
Switch Circuits - Test ......................................... 496
Variable Valve Actuator - Test............................. 498
Variable Valve Actuator Response - Test ............. 503
Water in Fuel - Test ........................................... 514
Service
Service Tool Features........................................ 517
Service Tool Error Identifiers .............................. 565
Customer Passwords ........................................ 571
Factory Passwords............................................ 571
ECM Will Not Accept Factory Passwords ............ 571
Electronic Service Tool Does Not Communicate .. 572
Codes that Inhibit Operation of Aftertreatment
System ........................................................... 578
Test ECM Mode ................................................ 582
Injector Trim File - Install .................................... 583
ECM Software - Install ....................................... 584
ECM - Replace ................................................. 584
DEF Pump - Replace......................................... 587
ARD Combustion Air Valve - Replace ................. 589
Electrical Connectors - Inspect ........................... 590
Cooling Fan - Calibrate ...................................... 593
Timing - Calibrate .............................................. 594
Index Section
Index................................................................ 601
M0070030-01 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:
i06632166 • 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.
The ECM provides outputs for the application control
An accident can often be avoided by recognizing system via the electrical connector to control lamps,
potentially hazardous situations before an accident solenoids, and other devices. Correctly configure the
occurs.
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. Caterpillar 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 Aftertreatment Regeneration Device (ARD) – The
control system. The system consists of a computer, ARD provides additional heat to convert the soot in
sensors, and software. The system performs these the DPF into gas. The ARD operates only when
functions: additional heat in the exhaust is needed.
Selective Catalyst Reduction (SCR) System – The
• Control of the engine
SCR system is used to reduce NOx emissions from
• Control of the Selective Catalyst Reduction (SCR) the engine. The SCR system is installed after the
DPF in the exhaust.
system
Software – Software in the ECM monitors the DPF
• Control of particulate emissions via the Clean and the ARD. The software controls the delivery of
Emission Module (CEM) fuel, combustion air, and the spark to the ARD. The
software also controls the amount of Diesel Exhaust
• Applications control system interface Fluid (DEF) being injected into the exhaust stream.
• Fault detection and reporting
6 M0070030-01
Introduction
Fault Detection and Reporting • High DPF #1 Soot Loading

The ECM monitors inputs from the sensors and • Aftertreatment Insufficient Temperature to
inputs from the applications control system. Software Complete Regeneration
in the ECM interprets the inputs. The software
determines if the inputs are operating correctly. A • Aftertreatment Fuel Injector #1 not responding
diagnostic trouble code is activated when the
software detects a problem with an input. These codes are the result of a fouled nozzle. The
regeneration system was unable to increase the
The ECM broadcasts the codes on two data links. exhaust gas temperature enough to regenerate the
The data links are the Perkins Data Link (PDL) and trap because the fittings or the nozzle failed. The
J1939. The electronic service tool must communicate “High DPF #1 Soot Loading” code was generated
on both data links to service the engine. If a problem because the trap was unable to regenerate. The
is suspected with one of the data links, refer to troubleshooting procedure to use in this case is the
Troubleshooting, “Data Link - Test”. “Aftertreatment Fuel Injector #1 not responding”
The codes can be displayed on the electronic service code, which will fix the other two issues.
tool and optional operator interfaces. Refer to
Troubleshooting, “Diagnostic Trouble Codes” for i06243428
additional information on diagnostic trouble codes
and a complete list of codes. Welding Precaution
Troubleshooting
As a reference, simplified schematics for each of the Proper welding procedures are necessary in
engine subsystems are included with each of the order to avoid damage to the A4 Electronic
circuit tests that are in this manual. For an accurate Control Module (ECM), A5 ECM, Diesel Exhaust
representation of the entire electrical schematic that Fluid Control Unit (DCU) if equipped, sensors,
is for your application, refer to the Electrical System and associated components. Also consider
Schematic. components that are for the driven equipment.
Remove the component that requires welding.
During troubleshooting, inspect all harness When welding on an engine that is equipped with
connections before any component is replaced. If an ECM and removal of the component is not
these connections are not clean and tight, continuous possible, the following procedure must be
electrical problems or intermittent electrical problems followed. This procedure provides the minimum
can result. Check that the wires are pushed into the amount of risk to the electronic components.
connectors completely. Make sure that the
connections are tight before other tests are made. 1. Stop the engine. Remove the electrical power from
the ECM.
Failure of an electrical component may cause the
failure of other components. Always attempt to 2. Ensure that the fuel supply to the engine is turned
correct the cause of an electrical failure before you off.
replace a component. If wire insulation is punctured,
repair the damage. 3. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is installed,
Troubleshooting Associated Codes
open the switch.
Certain systems will display multiple codes for 4. Disconnect all electronic components from the
troubleshooting . The “Associated Codes” must be
used to troubleshoot the system. The codes should wiring harnesses. Electronic components include
be viewed as separate levels of troubleshooting. For the following components:
example, a “High DPF #1 Soot Loading” code is
generated if the engine is allowed to run after an • Electronic components for the driven
ARD warning is displayed. This main code is not the equipment
code that requires troubleshooting.
• A4 ECM
The system is designed to display the codes for this
separate level of troubleshooting as an “Associated • A5 ECM
Code” . The “Associated Code” is the diagnostic or
the event code that needs to have the • DCU
troubleshooting procedure followed.
• Sensors
The following paragraph is an example of
troubleshooting the engine system with
“ Associated Codes”” .
After connecting the electronic service tool to an
engine, the following codes are displayed:
M0070030-01 7
Introduction
Table 1
NOTICE
Do NOT use electrical components (ECM or sensors) Service Tools
or electronic component grounding points for ground-
ing the welder. Part Description
Number
N/A 4 mm Allen Wrench
28170079 Wedge Removal Tool
T400920 Wire Removal Tool (14-GA TO 18-GA, RED)
CH11155 Crimp Tool (12−AWG TO 18−AWG)
GE50038 Transducer
GE50039 Transducer Adapter
GE50040 Cable As
CVT0019 Adapter Cable As (3-PIN BREAKOUT)
T400922 Adapter Cable As (40-PIN BREAKOUT)

T400923 Harness (40-PIN)
(For ADEM 2 ECM (two 40-pin connectors))
GE50037 / Adapter Cable As (70-PIN BREAKOUT)

2900A025 (For ADEM 3 ECM (two 70-pin connectors) and
for ADEM 4 ECM (one 70-pin connector and one
120-pin connector))
T400924 Adapter Cable As (120-PIN BREAKOUT)

(For ADEM 4 ECM (one 70-pin connector and one
Illustration 1 g01143634 120-pin connector))
Service welding guide (typical diagram) N/A Torque Wrench (capable of applying 1.5 N·m
(13.3 lb in))
5. When possible, connect the welder ground clamp
Repair Kits for Connectors
directly to the engine component that will be
welded. Place the clamp as close as possible to U5MK1110 Connector Repair Kit (AMPSEAL)
the weld. A close connection will reduce the Connector Repair Kit (Deutsch connector )
U5MK8194
possibility of welding current damage to the engine
bearings, to the electrical components, and to Bypass Harnesses for the ECM
other components. T400925 Power Cable
(Stand alone cable for ADEM 2 ECM)
6. Protect the wiring harnesses from welding debris
and/or from the welding spatter. 2900A038 Wiring Harness (ECM BYPASS)
(The bypass harness connects to the battery. The
7. Use standard welding procedures to weld the bypass harness is used with the following har-
materials together. nesses for different types of electronic control
modules.)
i05957511
T400926 Harness (ENGINE ECM BYPASS)
(For ADEM 3 ECM and ADEM 4 ECM)
Electronic Service Tools
28170107 Harness (ENGINE ECM BYPASS)
(For A4:E2 ECM (Two 64-pin connectors))
Service Tools Two short jumper wires may be needed to check the
continuity of some wiring harness circuits by shorting
Most of the tools that are listed in Table 1 are two adjacent terminals together in a connector. A
required to enable a service technician to perform the
test procedures in this manual. Some of the devices long extension wire may also be needed to check the
may be specific to the type of Electronic Control continuity of some wiring harness circuits.
Module (ECM) that is being used.
Optional Service Tools
Table 2 lists the optional service tools that may be
needed during testing or repair.
8 M0070030-01
Introduction
Table 2
Part Number Description Table 3
U5MK1092 Spoon Probe Kit (MULTIMETER) Service Tools for the Use of the Electronic Service
Tool
- Suitable Digital Pressure Indicator
or or Part Number Description
- Engine Pressure Group
-(1) Single Use Program License
- Suitable Battery Load Tester
-(1) Data Subscription for All Engines
- Suitable Temperature Adapter
(MULTIMETER) 27610164 TIPSS Adapter Kit (Electronic Service Tool to
the ECM interface)
2900A038 Harness as or
27610401 Perkins CA3 Kit
(1) Refer to Perkins Engine Company Limited.
Perkins Electronic Service Tool
The Electronic Service Tool can display the following Note: For more information on the Electronic Service
information: Tool and the PC requirements, refer to the
documentation that accompanies the software for the
• Status of all pressure sensors and temperature Electronic Service Tool.
sensors
• Programmable parameter settings Connecting the Electronic Service Tool

and the TIPSS Adapter
• Active diagnostic codes and logged diagnostic
codes
• Logged events
• Histograms
The Electronic Service Tool can also be used to
perform the following functions:
• Diagnostic tests
• Calibrations
• Programming of flash file
• Parameter programming
• Copy configuration function for Electronic Control
Module (ECM) replacement
• Data logging
• Graphs (real time)

Table 3 lists the service tools that are required in
order to use the Electronic Service Tool.
Illustration 2 g03738342
(1) Personal Computer (PC)
(2) Adapter Cable (Computer Serial Port)
(3) TIPSS adapter
(4) Adapter Cable Assembly
Note: Items (2), (3) and (4) are part of the TIPSS
adapter kit.
M0070030-01 9
Introduction
Use the following procedure in order to connect the Use the following procedure in order to connect the
Electronic Service Tool and the TIPSS Adapter. Electronic Service Tool and the CA3 Adapter.
1. Turn the keyswitch to the OFF position. 1. Turn the keyswitch to the OFF position.
2. Connect cable (2) between the “COMPUTER” end 2. Connect cable (2) between the “COMPUTER” end
of TIPSS adapter (3) and the RS232 serial port of of CA3 adapter (3) and a USB port of PC (1).
PC (1).
3. Connect cable (4) between the “DATA LINK” end
Note: The Adapter Cable Assembly (4) is required to of CA3 adapter (3) and the service tool connector.
connect to the USB port on computers that are not 4. Place the keyswitch in the ON position. If the
equipped with an RS232 serial port.
Electronic Service Tool and the CA3 adapter do
3. Connect cable (4) between the “DATA LINK” end not communicate with the Electronic Control
of TIPSS adapter (3) and the service tool Module (ECM), refer to the diagnostic procedure
connector. Troubleshooting, “Electronic Service Tool Does
Not Communicate”.
4. Place the keyswitch in the ON position. If the
Electronic Service Tool and the TIPSS adapter do
not communicate with the Electronic Control
Module (ECM), refer to the diagnostic procedure
Troubleshooting, “Electronic Service Tool Does
Not Communicate”.
Connecting the Electronic Service Tool

and the CA3 Kit
(1) Personal Computer (PC)
(2) Adapter Cable (Computer Serial Port)
(3) CA3 adapter
(4) Adapter Cable Assembly
Note: Items (2), (3) and (4) are part of the CA3 kit.
10 M0070030-01
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
i06841069
should occur relative to the top center. The ECM then
provides the signal to the injector at the desired time.
System Overview
Fuel Injection
The ECM sends high-voltage signals to the injector
The engine is designed for electronic control of most solenoids to energize the solenoids. By controlling
engine operating functions. The electronic system the timing and the duration of the high-voltage
consists of an Electronic Control Module (ECM), the signals, the ECM can control the following aspects of
wiring harness, switches, sensors, and fuel injectors. injection:
The engine ECM receives information from the
sensors and the switches on the engine. The engine • Injection timing
ECM processes the information that is collected to
control the engine. By altering the fuel delivery with • Fuel delivery
the fuel injectors, the engine ECM controls the speed
and the power that is produced by the engine. The The flash file inside the ECM establishes certain
engine is controlled by the A4E4 ECM. The limits on the amount of fuel that can be injected. The
aftertreatment system is controlled by the A5E2 “FRC Fuel Limit” is a limit that is based on the intake
ECM. The DEF pump and DEF line heaters are manifold pressure. The “FRC Fuel Limit” is used to
controlled by the DCU. control the air/fuel ratio for control of emissions.
When the ECM senses a higher intake manifold
The following information provides a general pressure, the ECM increases the “FRC Fuel Limit” . A
description of the control system. Refer to the higher intake manifold pressure indicates that there is
Systems Operation manual for detailed information more air in the cylinder. When the ECM increases the
about the control system. “FRC Fuel Limit” , the ECM changes the control
signal to the injector. The signal will allow more fuel
into the cylinder.
System Operation
The “Rated Fuel Limit” is a limit that is based on the
Engine Governor power rating of the engine and on the engine rpm.
The “Rated Fuel Limit” is like the rack stops and the
The ECM governs the engine. The ECM determines torque spring on a mechanically governed engine.
the timing, the injection pressure, and the amount of The “Rated Fuel Limit” provides the power curves
fuel that is delivered to each cylinder. These factors and the torque curves for a specific engine family and
are based on the actual conditions and on the a specific engine rating. All these limits are
desired conditions at any given time during starting determined at the factory. These limits cannot be
and operation. changed.
The ECM uses the throttle position sensor to Other ECM Functions for
determine the desired engine speed. The ECM
compares the desired engine speed to the actual Performance
engine speed. The actual engine speed is The ECM may also provide enhanced control of the
determined through interpretation of the signals that engine for functions such as retarding the engine and
are received by the ECM from the engine speed/ controlling the cooling fan. Refer to Troubleshooting,
timing sensors. If the desired engine speed is greater “Configuration Parameters” for supplemental
than the actual engine speed, the ECM requests that information about the systems that can be monitored
more fuel is injected to increase engine speed. by the ECM.
Timing Considerations Programmable Parameters

Certain parameters that affect engine operation may
Once the ECM has determined the amount of fuel be changed with the electronic service tool. The
that is required, the ECM must determine the timing parameters are stored in the ECM, and the
of the fuel injection. parameters are protected from unauthorized changes
by passwords. These parameters are either system
configuration parameters or customer parameters.
M0070030-01 11
System configuration parameters are set at the

factory. System configuration parameters affect
emissions or power ratings within an engine family.
Factory passwords must be obtained and factory
passwords must be used to change the system
configuration parameters.
Some of the parameters may affect engine operation
in an unusual way. An operator might not expect this
type of effect. Without adequate training, these
parameters may lead to power complaints or
performance complaints even though the engines
performance is to the specification.
Customer parameters are variable. Customer
parameters can be used to affect the characteristics
of the engine. Limits are set by the factory and by the
monitoring system.
Customer passwords may be required to change
customer specified parameters.
Refer to Troubleshooting, “Configuration Parameters”
for additional information on this subject.
Passwords
System configuration parameters are protected by
factory passwords. Factory passwords are calculated
on a computer system that is available only to
Perkins distributors. Since factory passwords contain
alphabetic characters, only the electronic service tool
may change system configuration parameters.
Customer parameters can be protected by customer
passwords. The customer passwords are
programmed by the customer. Factory passwords
can be used to change customer passwords if
customer passwords are lost.
Refer to Troubleshooting, “Customer Passwords”
and Troubleshooting, “Factory Passwords” for
additional information on this subject.
i06633368
Component Location
Electronic Control Circuit Diagram

A4:E4 ECM
12 M0070030-01
A5:E2 ECM
M0070030-01 13
14 M0070030-01
Sensor Locations
Table 4
Component Name Conversion to Electronic Service Tool Dis-
play Name
Electronic Service Tool Dis- Troubleshooting Guide Com-

play Component Name ponent Name
Engine charge air cooler #1 out- Charge air cooler outlet

let temperature temperature
ARD fuel flow diverter actuator ARD fuel diverter valve

status
EGR differential pressure NRS delta pressure sensor
EGR intake pressure (absolute) NRS absolute pressure sensor
EGR temperature NRS temperature sensor
EGR valve NRS actuator

Engine exhaust manifold bank Balance valve solenoid
#1 flow balance valve solenoid
DPF #1 intake pressure DPF intake pressure
DPF #1 intake temperature DPF inlet temperature sensor
ARD fuel pressure #1 Pilot fuel pressure sensor
ARD fuel pressure #2 Main fuel pressure sensor
Aftertreatment #1 ignition ARD ignition coil

transformer
Aftertreatment #1 fuel injector Heated nozzle
#1 heater
Aftertreatment #1 exhaust gas Flame detection temperature
temperature #1 sensor
Aftertreatment #1 secondary air Combustion air inlet pressure

pressure sensor
M0070030-01 15
(A) Refer to “View A” for a detailed (C) Refer to “View C” for a detailed (E) Refer to “View E” for a detailed
illustration. illustration. illustration.
(B) Refer to “View B” for a detailed (D) Refer to “View D” for a detailed (F) Refer to “View F” for a detailed
illustration. illustration. illustration.
Refer to Table 4 when referencing electronic service

tool service test names and component location
names in the troubleshooting guide.
16 M0070030-01
View A
(1) Fuel temperature sensor (2) Fuel pressure sensor
M0070030-01 17
View B
(1) Charge air cooler outlet temperature (2) TDC probe connector
18 M0070030-01
View C
(1) NRS outlet pressure sensor (2) NRS differential pressure sensor (3) NRS temperature sensor
M0070030-01 19
View D
(1) Terminating resistor (3) Crankcase pressure sensor

(2) Oil pressure sensor (4) Barometric pressure sensor
20 M0070030-01
View E
(1) Primary speed/timing sensor (2) A/C and alternator connector
M0070030-01 21
View F
(1) Intake manifold air pressure sensor (2) Camshaft speed/timing sensor
22 M0070030-01
Clean Emission Module (CEM) Side

View
CEM ( typical )
(1) DOC/Inlet Cap (4) DPF Outlet cap (7) SCR Inlet Cap
(2) DPF inlet temperature sensor (5) SCR Outlet cap
(3) Diesel Particulate Filter (6) Exhaust outlet
M0070030-01 23
CEM Control Panel
CEM control panel ( typical )
(1) Combustion air intake (7) Differential pressure port (13) Pilot fuel pressure sensor
(2) Differential pressure port (8) Aftertreatment identification module (14) Main fuel pressure sensor
(3) ARD Nozzle heater relay (9) CEM Harness connector (15) Coil for the spark plug
(4) Combustion air inlet pressure sensor (10) Pilot fuel solenoid (16) Combustion air control group
(5) Differential pressure sensor (11) Main fuel solenoid
(6) Temperature sensor (12) Coolant in/out
24 M0070030-01
ARD Head and Dosing Unit Overview
(1) Flame detection temperature sensor (4) Main fuel filter/fitting (7) Coolant in/out
(2) Heated nozzle port (5) ARD head (8) Ground point
(3) Pilot fuel filter/fitting (6) Spark plug (9) Combustion air inlet
M0070030-01 25
(10) Diverter valve (11) Priming Pump (12) Pressure regulator
26 M0070030-01
DEF Dosing Unit (Top)
(1) Coolant Supply Fitting (5) Suction Line (Line Heater #3) (9) DEF Header Connector
(2) Line Heater #1 Connector (6) DEF Header (10) Coolant Return Fitting
(3) Line Heater #3 Connector (7) Backflow Line (Line heater #1) (11) Pressure Line Connection (Line Heater
(4) Coolant Supply to DEF Header (8) Coolant Supply to DEF Pump #2)
M0070030-01 27
DEF Dosing Unit (Right Side)
(1) DEF Filter Housing Cover (4) Coolant Return Fitting (7) 53-pin Connector
(2) Sensor Interface Harness (5) Diesel Exhaust Fluid Control Unit (DCU) (8) Voltage Load Protection Module (VLPM)
(3) Power Supply Harness (6) 86-pin Connector
28 M0070030-01
DEF Dosing Unit (Left Side)
(1) Line Heater Relay (5) DEF Pump (9) Terminating Resistor
(2) Main Power Relay (6) Coolant Return Fitting (10) DEF Filter Housing Cover
(3) Coolant Supply Fitting (7) Power Supply Harness
(4) Coolant Diverter Valve (8) Sensor Interface Harness
M0070030-01 29
DEF Dosing Unit (Injector)
(1) DEF Injector (2) Coolant Lines
i06633447 Selective Catalyst Reduction (SCR)

The SCR system is used to reduce the NOx
Diesel Particulate Filter emissions from the engine. The SCR system is used
Regeneration during normal engine operation. The SCR catalyst
should not have to be cleaned or serviced. A problem
with the SCR system will cause a diagnostic or event
code to become active.
Regeneration
The Diesel Particulate Filter (DPF) traps both soot
and ash. Regeneration is the removal of soot from
the DPF. The Aftertreatment Regeneration Device
(ARD) is used to regenerate the DPF. The long-term
buildup of ash is removed through a manual cleaning
process. Refer to Operation and Maintenance
Manual, “Diesel Particulate Filter - Clean” for more
information on the service of the DPF.
For additional information on the regeneration of the
DPF, refer to Systems Operation/Testing and
Adjusting.
30 M0070030-01
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. Some of the parameters
are protected by factory passwords. Some
i06896501 parameters cannot be changed. Some applications
do not allow any changes to the programmable
Engine Monitoring System monitoring system. Parameters that are protected by
factory passwords can only be changed by dealer
personnel.
The Electronic Control Module (ECM) provides a
comprehensive, programmable engine monitoring
Viewing or Changing the Settings
system for this engine. The ECM monitors specific of the Monitoring System
engine operating parameters to detect abnormal
conditions that may develop. The ECM will generate Use the following procedure to view the parameter
an event code if a specific engine parameter exceeds settings and/or change the parameter settings:
an acceptable range that is defined by the engine 1. Select the “Service/Monitoring System” screen on
monitoring system. The ECM will react with an action
that depends the severity of the condition. For the electronic service tool.
information on event codes, refer to Troubleshooting,
“Event Codes”. Note: Ensure that you select the correct ECM for the
parameters that are being changed before
The following actions may be initiated by the ECM. continuing.
These actions depend on the severity of the
condition. 2. Highlight the desired parameter. Then click the
“Change” button in the lower left corner of the
• Illumination of a warning lamp or warning alarm screen.
• Engine derates The “Change Monitor System” screen will appear.
• Engine shutdown 3. Change the “State” of the parameter.
Three possible responses may be available for each 4. Set the “Trip Point” and the “Delay Time” according
parameter. Some of the responses are not available to the “Allowed Values” that are displayed in the
for some of the parameters. Refer to Table 5 . lower half of the screen.
Table 5
5. Click the “OK” button.
Indicators (1), (2), and (3)
If a password is required, the “Enter Passwords”
Warning Category screen will appear. Enter the correct passwords
Indicator Severity and then click the “OK” button.
(1) Least Severe
Note: If a factory password is required, the “Enter
(2) Moderate Severity Factory Passwords” screen will appear. Refer to
Troubleshooting, “Factory Passwords” for information
(3) Most Severe that is related to obtaining factory passwords.
Use the electronic service tool to perform the The new settings will be effective immediately.
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.
M0070030-01 31
Note: Factory passwords are only available to Codes can have two different states:
service technicians from a Cat dealership.
Customers of Caterpillar do not have access to the • Active
Cat Factory Password System (FPS).
• Logged
i06633574
Active Codes
Diagnostic Capabilities 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:
Diagnostic Codes
• Troubleshooting, “Diagnostic Trouble Codes”
The engines Electronic Control Module (ECM) can
monitor the circuitry between the ECM and the • Troubleshooting, “Event Codes”
engines components. The ECM can also monitor the
engines operating conditions. If the ECM detects a
problem, a code is generated. Logged Codes
There are two categories of codes: The codes are logged and stored in the ECM
memory. The problem may have been repaired and/
• Diagnostic code or the problem may no longer exist. If the system is
powered, an active diagnostic code may be
• Event code generated whenever a component is disconnected. If
the component is reconnected, the code is no longer
Diagnostic Code – A diagnostic code indicates an active but the code may become logged.
electrical problem such as a short circuit or an open
circuit in the engines wiring or in an electrical Logged codes may not indicate that a repair is
component. needed. The problem may have been temporary.
Logged codes may be useful to help troubleshoot
intermittent problems. Logged codes can also be
Event Code – An event code is generated by the used to review the performance of the engine and of
detection of an abnormal engine operating condition. the electronic system.
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.
32 M0070030-01
An extra status screen is available for the Enhanced accessed through the electronic service tool.
Troubleshooting Indicator (ETI). The screen is
i06701508
Electrical Connectors
Connectors for the Electronic Control

Module (ECM)
Locations of the components at the Engine ECM
M0070030-01 33
(1) P2 ECM connector (ECM side) (3) P2 ECM connector (harness side) (5) Engine ECM
(2) P1 ECM connector (ECM side) (4) P1 ECM connector (harness side)
Locations of the components at the Aftertreatment ECM
(6) P2 ECM connector (ECM side) (8) P2 ECM connector (harness side) (10) Aftertreatment ECM
(7) P1 ECM connector (ECM side) (9) P1 ECM connector (harness side)
34 M0070030-01
Locations of the components at the Aftertreatment ECM
(11) 53-pin Connector (13) Diesel Exhaust Fluid Control Unit
(12) 86-pin Connector (DCU)
M0070030-01 35
Injector Connectors
Connectors at the Valve Cover
Connector at the Injector
Typical MR injector
Typical HD injector
36 M0070030-01
Sensor Connectors Connectors for the Termination Resistor
Analog Sensor Connector (active)
Analog Sensor Connector (passive)

Engine Speed/Timing Connector
M0070030-01 37
Ampseal Connector (typical)
Deutsch Connectors (typical)
38 M0070030-01
Configuration Parameters
i06633590
Use this procedure if the diagnostic code in Table 6 is

active.
Table 6
Codes That Relate to Configuration Parameters
Code Description
J1939 Code PDL Code (code descriptions may vary) Comments
The engine Electronic Control
Module (ECM) detects that one
or more of the programmable
parameters have not been
Programmed Parameter Fault : Er-
630-2 268-2 programmed.
ratic, Intermittent, or Incorrect
The ECM may use a default tor-
que map or the ECM may limit
the engine to low idle.
The code is active only.
Follow the troubleshooting procedure to identify the root cause of the problem.
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.
M0070030-01 39
Typical configuration screen
1. Connect to the electronic service tool.

2. Select the Service tab.
3. Select the Configuration tab to view the
If an ECM is replaced, the appropriate parameters
must be copied from the old ECM. Copy the
parameters with the “Copy Configuration” feature of
the electronic service tool. The “Copy Configuration”
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.
40 M0070030-01
Check Programmable Parameters

630–2 (268-2)
If a programmable parameter has not been

programmed, the ECM will generate a 268-2 or 630-2
diagnostic code. The programmable parameter that
is not programmed will be listed under the code.
Illustration 34 shows the parameters that are not
programmed under the 268-2 code. The
unprogrammed parameters will be set to default.
Certain aspects of the engines performance and
engine monitoring may be affected.
If “Injector Trim” is displayed below a 268-2 or 630-2
diagnostic code on the electronic service tool, refer to
Troubleshooting, “Injector Trim File - Install”.
M0070030-01 41
Diagnostic Trouble Codes
i06918970
Diagnostic Trouble Codes in J1939

Order
Table 7 lists the diagnostic trouble codes that apply to
the engine. 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 7
List of Diagnostic Trouble Codes
J1939 Code and Description PDL Code and Description Troubleshooting Procedure
- 544–2 Troubleshooting, “Cooling Fan Speed - Test”

Engine Cooling Fan Speed Sensor : Erratic,
Intermittent, or Incorrect
- 544–8 Troubleshooting, “Cooling Fan Speed - Test”

- 1076–5 Troubleshooting, “Cooling Fan Control - Test”

Engine Cooling Fan Bypass Solenoid : Current
Below Normal
- 1076–6 Troubleshooting, “Cooling Fan Control - Test”
Above Normal
- 1937–2 Troubleshooting, “Coolant Pressure Is Low”
Engine Coolant Flow Switch : Erratic, Intermit-
tent, or Incorrect
29–2 774–2 Troubleshooting, “Speed Control - Test”

Accelerator Pedal Position #2 : Erratic, Inter- Secondary Throttle Position Sensor : Erratic,
mittent, or Incorrect Intermittent, or Incorrect

Accelerator Pedal Position #2 : Voltage Above Secondary Throttle Position Sensor : Voltage
Normal Above Normal
Accelerator Pedal Position #2 : Voltage Below Secondary Throttle Position Sensor : Voltage
Normal Below Normal
Accelerator Pedal Position #2 : Abnormal Fre- Secondary Throttle Position Sensor : Abnor-
quency, Pulse Width, or Period mal Frequency, Pulse Width, or Period

Accelerator Pedal Position #1 : Erratic, Inter- Throttle Position Sensor : Erratic, Intermittent,
mittent, or Incorrect or Incorrect
(continued)
42 M0070030-01
(Table 7, contd)
Accelerator Pedal Position #1 : Voltage Above Throttle Position Sensor : Voltage Above
Normal Normal
Accelerator Pedal Position #1 : Voltage Below Throttle Position Sensor : Voltage Below
Normal Normal
Accelerator Pedal Position #1 : Abnormal Fre- Throttle Position Sensor : Abnormal Fre-
quency, Pulse Width, or Period quency, Pulse Width, or Period
97–3 3547–3 Troubleshooting, “Water in Fuel - Test”

Water In Fuel Indicator : Voltage Above Water in Fuel System Switch : Voltage Above
Normal Normal
100–3 100–3 Troubleshooting, “Sensor Signal (Analog, Ac-
Engine Oil Pressure : Voltage Above Normal Engine Oil Pressure Sensor : Voltage Above tive) - Test”
Normal
Engine Oil Pressure : Voltage Below Normal Engine Oil Pressure Sensor : Voltage Below tive) - Test”
Normal
Engine Crankcase Pressure : Voltage Above Crankcase Air Pressure Sensor : Voltage tive) - Test”
Normal Above Normal
Engine Crankcase Pressure : Voltage Below Crankcase Air Pressure Sensor : Voltage Be- tive) - Test”
Normal low Normal
101–13 101–13 Troubleshooting, “Sensor Calibration Required
Engine Crankcase Pressure : Out of Crankcase Air Pressure Sensor : Out of - Test”
Calibration Calibration
107–3 582–3 Troubleshooting, “Switch Circuits - Test”
Engine Air Filter 1 Differential Pressure : Volt- Air Filter Differential Pressure Switch : Voltage
age Above Normal Above Normal

Barometric Pressure : Voltage Above Normal Barometric Pressure Sensor : Voltage Above tive) - Test”
Normal
Barometric Pressure : Voltage Below Normal Barometric Pressure Sensor : Voltage Below tive) - Test”
Normal
108–21 3528–21 Troubleshooting, “Sensor Supply - Test”
Barometric Pressure : Data Drifted Low Barometric Pressure Sensor : Data Drifted
Low
Engine Coolant Pressure : Voltage Above Engine Coolant Pump Outlet Pressure Sensor tive) - Test”
Normal : Voltage Above Normal

Engine Coolant Pressure : Voltage Below Engine Coolant Pump Outlet Pressure Sensor tive) - Test”
Normal : Voltage Below Normal
110–3 110–3 Troubleshooting, “Sensor Signal (Analog, Pas-

Engine Coolant Temperature : Voltage Above Engine Coolant Temperature Sensor : Voltage sive) - Test”
Normal Above Normal
Engine Coolant Temperature : Voltage Below Engine Coolant Temperature Sensor : Voltage sive) - Test”
Normal Below Normal
(continued)
M0070030-01 43
(Table 7, contd)
157-3 1797-3
Troubleshooting, “Sensor Signal (Analog, Ac-
Engine Injector Metering Rail #1 Pressure : Fuel Rail Pressure Sensor : Voltage Above
tive) - Test”
Voltage Above Normal Normal
157-4 1797-4
Troubleshooting, “Sensor Signal (Analog, Ac-
Engine Injector Metering Rail #1 Pressure : Fuel Rail Pressure Sensor : Voltage Below
tive) - Test”
Voltage Below Normal Normal
168–3 168–3 Troubleshooting, “Electrical Power Supply -

Battery Potential / Power Input #1 : Voltage Electrical System Voltage : Voltage Above Test”
Above Normal Normal
Battery Potential / Power Input #1 : Voltage Electrical System Voltage : Voltage Below Test”
Below Normal Normal
Ambient Air Temperature : Voltage Above Ambient Air Temperature Sensor : Voltage sive) - Test”
Normal Above Normal
Ambient Air Temperature : Voltage Below Ambient Air Temperature Sensor : Voltage Be- sive) - Test”
Normal low Normal
Engine Air Inlet Temperature : Voltage Above Air Inlet Temperature Sensor : Voltage Above sive) - Test”
Normal Normal
Engine Air Inlet Temperature : Voltage Below Air Inlet Temperature Sensor : Voltage Below sive) - Test”
Normal Normal
Engine Fuel Temperature 1 : Voltage Above Fuel Temperature Sensor : Voltage Above sive) - Test”
Normal Normal
Engine Fuel Temperature 1 : Voltage Below Fuel Temperature Sensor : Voltage Below sive) - Test”
Normal Normal
Engine Oil Temperature 1 : Voltage Above Engine Oil Temperature Sensor : Voltage sive) - Test”
Normal Above Normal
Engine Oil Temperature 1 : Voltage Below Engine Oil Temperature Sensor : Voltage Be- sive) - Test”
Normal low Normal
190–8 190–8 Troubleshooting, “Speed/Timing - Test”
Engine Speed : Abnormal Frequency, Pulse Engine Speed Sensor : Abnormal Frequency,
Width, or Period Pulse Width, or Period

EGR Differential Pressure : Voltage Above EGR Differential Pressure Sensor : Voltage tive) - Test”
Normal Above Normal
EGR Differential Pressure : Voltage Below EGR Differential Pressure Sensor : Voltage tive) - Test”
Normal Below Normal
EGR Differential Pressure : Out of Calibration EGR Differential Pressure Sensor : Out of - Test”
Calibration
EGR Temperature : Voltage Above Normal EGR Temperature Sensor : Voltage Above sive) - Test”
Normal
(continued)
44 M0070030-01
(Table 7, contd)
EGR Temperature : Voltage Below Normal EGR Temperature Sensor : Voltage Below sive) - Test”
Normal
Auxiliary Temperature #1 : Voltage Above Auxiliary Temperature Sensor : Voltage Above sive) - Test”
Normal Normal
Auxiliary Temperature #1 : Voltage Below Auxiliary Temperature Sensor : Voltage Below sive) - Test”
Normal Normal
Auxiliary Temperature #2 : Voltage Above Auxiliary Temperature Sensor #2 : Voltage sive) - Test”
Normal Above Normal
Auxiliary Temperature #2 : Voltage Below Auxiliary Temperature Sensor #2 : Voltage Be- sive) - Test”
Normal low Normal
625–14 246–14 Troubleshooting, “Data Link Configuration Sta-
Proprietary Data Link : Special Instruction Proprietary CAN Data Link : Special tus - Test”
Instruction
626–5 2417–5 Troubleshooting, “Ether Starting Aid - Test”
Engine Start Enable Device 1 : Current Below Ether Injection Control Solenoid : Current Be-
Normal low Normal
Engine Start Enable Device 1 : Current Above Ether Injection Control Solenoid : Current
Normal Above Normal
630-2 268-2 Troubleshooting, “Programmable Parameters”
Calibration Memory : Erratic, Intermittent, or Programmed Parameter Fault : Erratic, Inter-
Incorrect mittent, or Incorrect
631–2 253–2 Troubleshooting, “ECM Software - Install”

Calibration Module : Erratic, Intermittent, or Personality Module : Erratic, Intermittent, or
Incorrect Incorrect
637–11 261–11 Troubleshooting, “Timing - Calibrate”
Engine Timing Sensor : Other Failure Mode Engine Timing Offset fault

Engine Timing Sensor : Out of Calibration Engine Timing Calibration : Out of Calibration
639–9 247–9 Troubleshooting, “Data Link - Test”

J1939 Network #1 : Abnormal Update Rate SAE J1939 Data Link : Abnormal Update Rate

J1939 Network #1 : Special Instruction SAE J1939 Data Link : Special Instruction
651–5 1–5 Troubleshooting, “Injector Solenoid - Test”

Engine Injector Cylinder #01 : Current Below Cylinder #1 Injector : Current Below Normal
Normal
Engine Injector Cylinder #01 : Current Above Cylinder #1 Injector : Current Above Normal
Normal
Normal
Normal
(continued)
M0070030-01 45
(Table 7, contd)
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
677–5 444–5 Troubleshooting, “Solenoid Valve - Test”
Engine Starter Motor Relay : Current Below Starter Motor Relay : Current Below Normal
Normal
Engine Starter Motor Relay : Current Above Starter Motor Relay : Current Above Normal
Normal
ECU 8 Volts DC Supply : Voltage Above 8 Volt DC Supply : Voltage Above Normal
Normal
ECU 8 Volts DC Supply : Voltage Below 8 Volt DC Supply : Voltage Below Normal
Normal
Engine Speed Sensor #2 : Abnormal Fre- Secondary Engine Speed Sensor : Abnormal
quency, Pulse Width, or Period Frequency, Pulse Width, or Period
1072–5 2533–5 Troubleshooting, “Retarder - Test”

Engine (Compression) Brake Output #1 : Cur- Compression Brake Low/High Solenoid #1 :
rent Below Normal Current Below Normal
Engine (Compression) Brake Output #1 : Cur- Compression Brake Low/High Solenoid #1 :
rent Above Normal Current Above Normal
Engine (Compression) Brake Output #2 : Cur- Compression Brake Medium/High Solenoid #1
rent Below Normal : Current Below Normal
Engine (Compression) Brake Output #2 : Cur- Compression Brake Medium/High Solenoid #1
rent Above Normal : Current Above Normal
(continued)
46 M0070030-01
(Table 7, contd)
Engine (Exhaust) Brake Output : Current Be- Engine Retarder Solenoid : Current Below
low Normal Normal
Engine (Exhaust) Brake Output : Current Engine Retarder Solenoid : Current Above
Above Normal Normal
Engine Turbocharger #1 Compressor Inlet Turbocharger #1 Compressor Inlet Pressure tive) - Test”
Pressure : Voltage Above Normal Sensor : Voltage Above Normal

Engine Turbocharger #1 Compressor Inlet Turbocharger #1 Compressor Inlet Pressure tive) - Test”
Pressure : Voltage Below Normal Sensor : Voltage Below Normal

J1939 Network #2 : Abnormal Update Rate SAE J1939 Data Link #2 : Abnormal Update
Rate
J1939 Network #2 : Special Instruction SAE J1939 Data Link #2: Special Instruction

J1939 Network #3 : Abnormal Update Rate SAE J1939 Data Link #3 : Abnormal Update
Rate
J1939 Network #3 : Special Instruction SAE J1939 Data Link #3: Special Instruction

Auxiliary Temperature #1 : Voltage Above Auxiliary Temperature Sensor : Voltage Above sive) - Test”
Normal Normal
Auxiliary Temperature #1 : Voltage Below Auxiliary Temperature Sensor : Voltage Below sive) - Test”
Normal Normal
Auxiliary Pressure #1 : Voltage Above Normal Auxiliary Pressure Sensor : Voltage Above tive) - Test”
Normal
Auxiliary Pressure #1 : Voltage Below Normal Auxiliary Pressure Sensor : Voltage Below tive) - Test”
Normal
1761–3 3130–3 Troubleshooting, “DEF Tank Sensor - Test”
Aftertreatment #1 DEF Tank Volume #1 : Volt- Aftertreatment #1 DEF Tank #1 Level Sensor :
age Above Normal Voltage Above Normal

Aftertreatment #1 DEF Tank Volume #1 : Volt- Aftertreatment #1 DEF Tank #1 Level Sensor :
age Below Normal Voltage Below Normal

Engine Charge Air Cooler Outlet Temperature Engine Charge Air Cooler #1 Outlet Tempera- sive) - Test”
: Voltage Above Normal ture Sensor : Voltage Above Normal

Engine Charge Air Cooler Outlet Temperature Engine Charge Air Cooler #1 Outlet Tempera- sive) - Test”
: Voltage Below Normal ture Sensor : Voltage Below Normal

EGR Valve Control : Current Below Normal EGR Valve Control : Current Below Normal
EGR Valve Control : Current Above Normal EGR Valve Control : Current Above Normal
(continued)
M0070030-01 47
(Table 7, contd)
2813–5 3239–5 Troubleshooting, “Air Shutoff - Test”
Engine Air Shutoff Command Status : Current Air Shutoff Relay : Current Below Normal
Below Normal
Engine Air Shutoff Command Status : Current Air Shutoff Relay : Current Above Normal
Above Normal
Engine Intake Valve Actuation System Oil Auxiliary Pressure Sensor : Voltage Above tive) - Test”
Pressure : Voltage Above Normal Normal

Engine Intake Valve Actuation System Oil Auxiliary Pressure Sensor : Voltage Below tive) - Test”
Pressure : Voltage Below Normal Normal

Engine Intake Valve Actuation System Oil Intake Valve Actuation System Oil Pressure
Pressure Control Valve : Current Below Solenoid : Current Below Normal
Normal
Engine Intake Valve Actuation System Oil Intake Valve Actuation System Oil Pressure
Pressure Control Valve : Current Above Solenoid : Current Above Normal
Normal
2949–7 1922–7 Troubleshooting, “Variable Valve Actuator Re-
Engine Intake Valve Actuation System Oil Intake Valve Actuation System Oil Pressure sponse - Test”
Pressure Control Valve : Not Responding Solenoid : Not Responding Properly
Properly
2950–5 1901–5 Troubleshooting, “Variable Valve Actuator -

Engine Intake Valve Actuator #1 : Current Be- Intake Valve Actuator #1 : Current Below Test”
low Normal Normal
Engine Intake Valve Actuator #1 : Current Intake Valve Actuator #1 : Current Above Test”
Above Normal Normal
Engine Intake Valve Actuator #1 : Not Re- Intake Valve Actuator #1 : Not Responding sponse - Test”
sponding Properly Properly

low Normal Normal
Above Normal Normal

low Normal Normal
Above Normal Normal
(continued)
48 M0070030-01
(Table 7, contd)
low Normal Normal
Above Normal Normal

low Normal Normal
Above Normal Normal

low Normal Normal
Above Normal Normal

Aftertreatment #1 DEF Tank Temperature : Aftertreatment #1 DEF Tank #1 Temperature
Voltage Above Normal Sensor : Voltage Above Normal

Aftertreatment #1 DEF Tank Temperature : Aftertreatment #1 DEF Tank #1 Temperature
Voltage Below Normal Sensor : Voltage Below Normal
3216–11 3655–11 Troubleshooting, “Sensor (Data Link Type) -

Aftertreatment #1 Intake NOx : Other Failure Aftertreatment #1 Intake NOx Level Sensor : Test”
Mode Other Failure Mode
Aftertreatment #1 Intake NOx : Failure Aftertreatment #1 Intake NOx Level Sensor : Test”
Failure
Aftertreatment #1 Outlet NOx : Other Failure Aftertreatment #1 Outlet #1 NOx Level Sensor Test”
Mode : Other Failure Mode
Aftertreatment #1 Outlet NOx : Failure Aftertreatment #1 Outlet #1 NOx Level Sensor Test”
: Failure
Aftertreatment #1 DPF Intake Temperature : DPF #1 Intake Temperature Sensor : Voltage tive) - Test”
Voltage Above Normal Above Normal

Aftertreatment #1 DPF Intake Temperature : DPF #1 Intake Temperature Sensor : Voltage tive) - Test”
Voltage Below Normal Below Normal
(continued)
M0070030-01 49
(Table 7, contd)
Aftertreatment #1 DPF Differential Pressure : DPF #1 Differential Pressure Sensor : Erratic, tive) - Test”
Erratic, Intermittent, or Incorrect Intermittent, or Incorrect

Aftertreatment #1 DPF Differential Pressure : DPF #1 Differential Pressure Sensor : Voltage tive) - Test”

Aftertreatment #1 DPF Differential Pressure : DPF #1 Differential Pressure Sensor : Voltage tive) - Test”
Voltage Below Normal Below Normal

Aftertreatment #1 DPF Differential Pressure : DPF #1 Differential Pressure Sensor : Out of - Test”
Out of Calibration Calibration
EGR Inlet Pressure : Voltage Above Normal EGR Intake Pressure Sensor : Voltage Above tive) - Test”
Normal
EGR Inlet Pressure : Voltage Below Normal EGR Intake Pressure Sensor : Voltage Below tive) - Test”
Normal
EGR Inlet Pressure : Out of Calibration EGR Intake Pressure Sensor : Out of - Test”
Calibration
EGR Inlet Pressure : Data Drifted Low EGR Intake Pressure Sensor : Data Drifted
Low
Aftertreatment #1 DEF Controller : Voltage Aftertreatment #1 Diesel Exhaust Fluid Con- Test”
Above Normal troller : Voltage Above Normal

Aftertreatment #1 DEF Controller : Voltage Be- Aftertreatment #1 Diesel Exhaust Fluid Con- Test”
low Normal troller : Voltage Below Normal

Aftertreatment #1 DEF Controller : Abnormal Aftertreatment #1 Diesel Exhaust Fluid Con-
Update Rate troller : Abnormal Update Rate

Aftertreatment #1 DEF Controller : Failure Aftertreatment #1 Diesel Exhaust Fluid Con- Test”
troller : Failure
Aftertreatment #1 DEF Dosing Unit : Current Aftertreatment #1 Diesel Exhaust Fluid Dosing
Below Normal Valve Actuator : Current Below Normal
Aftertreatment #1 DEF Dosing Unit : Current Aftertreatment #1 Diesel Exhaust Fluid Dosing
Above Normal Valve Actuator : Current Above Normal
3361–7 3821–7 Troubleshooting, “DEF Module Does Not
Catalyst Dosing Unit : Not Responding Aftertreatment #1 Diesel Exhaust Fluid Dosing Respond”
Properly Valve Actuator : Not Responding Properly

Catalyst Dosing Unit : Other Failure Mode Aftertreatment #1 Diesel Exhaust Fluid Dosing Respond”
Valve Actuator : Other Failure Mode
Catalyst Dosing Unit : Special Instruction Aftertreatment #1 Diesel Exhaust Fluid Dosing Respond”
Valve Actuator : Special Instruction
(continued)
50 M0070030-01
(Table 7, contd)
Aftertreatment #1 DEF Tank Heater : Current Aftertreatment #1 DEF Tank #1 Heater Coolant
Below Normal Diverter Solenoid : Current Below Normal
Aftertreatment #1 DEF Tank Heater : Current Aftertreatment #1 DEF Tank #1 Heater Coolant
Above Normal Diverter Solenoid : Current Above Normal
3363–7 3126–7 Troubleshooting, “DEF Temperature Is Low”
Aftertreatment 1 Diesel Exhaust Fluid Tank Aftertreatment #1 SCR Catalyst Reagent Tank
Heater : Not Responding Properly #1 Heater Coolant Diverter Solenoid : Not Re-
sponding Properly

Aftertreatment #1 Fuel Pressure Control : Cur- ARD Fuel Pressure #1 Control : Current Below
rent Below Normal Normal
Aftertreatment #1 Fuel Pressure Control : Cur- ARD Fuel Pressure #1 Control : Current Above
rent Above Normal Normal
Aftertreatment #1 Fuel Pressure #1 : Voltage ARD Fuel Pressure #1 Sensor : Voltage Above tive) - Test”
Above Normal Normal
Aftertreatment #1 Fuel Pressure #1 : Voltage ARD Fuel Pressure #1 Sensor : Voltage Below tive) - Test”
Below Normal Normal
3484–5 2465–5 Troubleshooting, “ARD Ignition - Test”
Aftertreatment #1 Ignition : Current Below Aftertreatment #1 Ignition Transformer Primary
Normal : Current Below Normal
Aftertreatment #1 Ignition : Current Above Aftertreatment #1 Ignition Transformer Primary
Normal : Current Above Normal
3487–5 2489–5 Troubleshooting, “ARD Combustion Air - Test”
Aftertreatment #1 Air Pressure Control : Cur- ARD Air Pressure Control Actuator : Current
rent Below Normal Below Normal
Aftertreatment #1 Air Pressure Control : Cur- ARD Air Pressure Control Actuator : Current
rent Above Normal Above Normal
3487–13 2489–13 Troubleshooting, “ARD Combustion Air Valve -
Aftertreatment #1 Air Pressure Control : Out of ARD Air Pressure Control Actuator : Out of Replace”
Aftertreatment #1 Air Pressure Actuator Posi- ARD Air Pressure Control Actuator Position
tion : Voltage Above Normal Sensor : Voltage Above Normal

Aftertreatment #1 Air Pressure Actuator Posi- ARD Air Pressure Control Actuator Position
tion : Voltage Below Normal Sensor : Voltage Below Normal

Sensor Supply Voltage 1 : Voltage Above 5 Volt Sensor DC Power Supply : Voltage
Normal Above Normal
Sensor Supply Voltage 1 : Voltage Below 5 Volt Sensor DC Power Supply : Voltage Be-
Normal low Normal
Sensor Supply Voltage 2 : Voltage Above 5 Volt Sensor DC Power Supply #2 : Voltage
Normal Above Normal
(continued)
M0070030-01 51
(Table 7, contd)
Sensor Supply Voltage 2 : Voltage Below 5 Volt Sensor DC Power Supply #2 : Voltage
Normal Below Normal
3511–11 3482–11 Troubleshooting, “DEF Pump Sensor Supply -
Sensor Supply Voltage 3 : Other Failure Mode Sensor Supply #3 : Other Failure Mode Test”

Aftertreatment #1 DEF Concentration: Erratic, Aftertreatment #1 DEF Concentration: Erratic,
Intermittent, or Incorrect Intermittent, or Incorrect

Aftertreatment #1 DEF Concentration: Failure Aftertreatment #1 DEF Concentration: Failure Test”
Engine Intake Manifold #1 Absolute Pressure : Intake Manifold Pressure Sensor : Voltage tive) - Test”

Engine Intake Manifold #1 Absolute Pressure : Intake Manifold Pressure Sensor : Voltage Be- tive) - Test”
Voltage Below Normal low Normal

Engine Intake Manifold #1 Absolute Pressure : Intake Manifold Pressure Sensor : Out of - Test”
Out of Calibration Calibration
Engine Intake Manifold #1 Absolute Pressure : Intake Manifold Pressure Sensor : Data Drifted
Data Drifted Low Low
DPF #1 Intake Pressure : Voltage Above DPF #1 Intake Pressure Sensor : Voltage tive) - Test”
Normal Above Normal
DPF #1 Intake Pressure : Voltage Below DPF #1 Intake Pressure Sensor : Voltage Be- tive) - Test”
Normal low Normal
DPF #1 Intake Pressure : Out of Calibration DPF #1 Intake Pressure Sensor : Out of - Test”
Calibration
DPF #1 Intake Pressure : Data Drifted Low DPF #1 Intake Pressure Sensor : Data Drifted
Low
Engine Injector Cylinder #1 Actuator #2 : Cur- Cylinder #1 Injector Actuator #2 : Current Be-
rent Below Normal low Normal
Engine Injector Cylinder #1 Actuator #2 : Cur- Cylinder #1 Injector Actuator #2 : Current
(continued)
52 M0070030-01
(Table 7, contd)
Aftertreatment #1 Secondary Air Pressure : Aftertreatment #1 Secondary Air Pressure tive) - Test”
Voltage Above Normal Sensor : Voltage Above Normal

Aftertreatment #1 Secondary Air Pressure : Aftertreatment #1 Secondary Air Pressure tive) - Test”
Voltage Below Normal Sensor : Voltage Below Normal

Aftertreatment #1 Secondary Air Pressure : Aftertreatment #1 Secondary Air Pressure - Test”
Out of Calibration Sensor : Out of Calibration
Aftertreatment #1 Secondary Air Pressure : Aftertreatment #1 Secondary Air Pressure
Data Drifted Low Sensor : Data Drifted Low
Aftertreatment #1 Fuel Pressure #2 : Voltage ARD Fuel Pressure #2 Sensor : Voltage Above tive) - Test”
Above Normal Normal
Aftertreatment #1 Fuel Pressure #2 : Voltage ARD Fuel Pressure #2 Sensor : Voltage Below tive) - Test”
Below Normal Normal
4212–5 291–5 Troubleshooting, “Cooling Fan Control - Test”
Fan Drive Bypass Command Status : Current Engine Cooling Fan Solenoid : Current Below
Below Normal Normal
Fan Drive Bypass Command Status : Current Engine Cooling Fan Solenoid : Current Above
Above Normal Normal
4212–13 1551–13 Troubleshooting, “Cooling Fan - Calibrate”
Fan Drive Bypass Command Status : Out of Engine Demand Fan System : Out of
4214–5 485–5 Troubleshooting, “Cooling Fan Reversing -
Engine Fan Reverse Actuator : Current Below Engine Fan Reversing Solenoid : Current Be- Test”
Normal low Normal
Engine Fan Reverse Actuator : Current Above Engine Fan Reversing Solenoid : Current Test”
Normal Above Normal
(continued)
M0070030-01 53
(Table 7, contd)
4215–3 267–3 Troubleshooting, “Shutdown (Ground Level) -
Ground-Level Shutdown Activated : Voltage Remote Shutdown Input : Voltage Above Test”
Above Normal Normal
Ground-Level Shutdown Activated : Voltage Remote Shutdown Input : Voltage Below Test”
Below Normal Normal
Aftertreatment #1 Transformer Secondary Out- Aftertreatment #1 Ignition Transformer Secon-
put : Current Below Normal dary : Current Below Normal
4301–3 3182–3 Troubleshooting, “ARD Nozzle Heater - Test”

Aftertreatment #1 Fuel Injector #1 Heater Con- Aftertreatment #1 Fuel Injector #1 Heater :
trol : Voltage Above Normal Voltage Above Normal

trol : Voltage Below Normal Voltage Below Normal

trol : Current Below Normal Current Below Normal
trol : Current Above Normal Current Above Normal
4334–3 3090–3 Troubleshooting, “DEF Pump Pressure Sensor
Aftertreatment #1 DEF #1 Pressure (absolute) Aftertreatment #1 DEF Pressure Sensor : Volt- - Test”
: Voltage Above Normal age Above Normal

Aftertreatment #1 DEF #1 Pressure (absolute) Aftertreatment #1 DEF Pressure Sensor : Volt- - Test”
: Voltage Below Normal age Below Normal
4334–7 3090–7 Troubleshooting, “DEF Pressure Is Low”

Aftertreatment 1 Diesel Exhaust Fluid Doser Aftertreatment #1 SCR Dosing Reagent Pres-
Absolute Pressure : Not Responding Properly sure Sensor : Not Responding Properly
4337–8 3096–8 Troubleshooting, “DEF Pump - Replace”

Aftertreatment #1 DEF Doser #1 Temperature Aftertreatment #1 DEF Temperature #1 Sensor
: Abnormal Frequency, Pulse Width, or Period : Abnormal Frequency, Pulse Width, or Period
4354–5 3110–5 Troubleshooting, “DEF Line Heater - Test”

Aftertreatment #1 DEF Line Heater #1 : Cur- Aftertreatment #1 DEF Line Heater #1 : Cur-
rent Below Normal rent Below Normal
rent Above Normal rent Above Normal
(continued)
54 M0070030-01
(Table 7, contd)
Aftertreatment #1 SCR Catalyst Intake Gas Aftertreatment #1 SCR Catalyst Intake Gas tive) - Test”
Temperature : Voltage Above Normal Temperature Sensor : Voltage Above Normal

Temperature : Voltage Below Normal Temperature Sensor : Voltage Below Normal
4374–5 3118–5 Troubleshooting, “DEF Pump Motor - Test”

Aftertreatment #1 DEF Pump #1 Motor Speed Aftertreatment #1 DEF Pump Motor Speed
: Current Below Normal Sensor : Current Below Normal
: Current Above Normal Sensor : Current Above Normal
: Abnormal Frequency, Pulse Width, or Period Sensor : Abnormal Frequency, Pulse Width, or
Period
4376–5 3862–5 Troubleshooting, “DEF Return Valve - Test”
Aftertreatment #1 DEF Return Valve : Current Aftertreatment #1 Diesel Exhaust Fluid Return
Below Normal Valve Solenoid : Current Below Normal
Aftertreatment #1 DEF Return Valve : Current Aftertreatment #1 Diesel Exhaust Fluid Return
Above Normal Valve Solenoid : Current Above Normal
Aftertreatment #1 DEF Return Valve : Not Re- Aftertreatment #1 Diesel Exhaust Fluid Return
sponding Properly Valve Solenoid : Not Responding Properly

Engine Exhaust Manifold Bank #1 Flow Bal- Engine Exhaust Manifold Bank #1 Flow Bal-
ance Valve Actuator Control : Current Below ance Valve Solenoid : Current Below Normal
Normal
ance Valve Actuator Control : Current Above ance Valve Solenoid : Current Above Normal
Normal
Aftertreatment #1 Fuel Pump Relay Control : Aftertreatment Fuel Pump Relay : Current Be-
Current Below Normal low Normal
Aftertreatment #1 Fuel Pump Relay Control : Aftertreatment Fuel Pump Relay : Current
Current Above Normal Above Normal
Aftertreatment #1 Fuel Flow Diverter Valve ARD Fuel Flow Diverter Actuator : Current Be-
Control : Current Below Normal low Normal
Aftertreatment #1 Fuel Flow Diverter Valve ARD Fuel Flow Diverter Actuator : Current
Control : Current Above Normal Above Normal
Aftertreatment #1 Fuel Pressure #2 Actuator ARD Fuel Pressure #2 Control Actuator : Cur-
Control : Current Below Normal rent Below Normal
Aftertreatment #1 Fuel Pressure #2 Actuator ARD Fuel Pressure #2 Control Actuator : Cur-
Control : Current Above Normal rent Above Normal
(continued)
M0070030-01 55
(Table 7, contd)
Aftertreatment #1 DEF Line Heater Relay : Aftertreatment #1 Diesel Exhaust Fluid Line
Current Below Normal Heater Relay : Current Below Normal

Aftertreatment #1 DEF Line Heater Relay : Aftertreatment #1 Diesel Exhaust Fluid Line
Current Above Normal Heater Relay : Current Above Normal
5576–2 3468–2 Troubleshooting, “Aftertreatment Identification

Aftertreatment #1 Identification : Erratic, Inter- Aftertreatment #1 Identification Number Mod- Module - Test”
mittent, or Incorrect ule : Erratic, Intermittent, or Incorrect

Aftertreatment #1 Identification : Abnormal Aftertreatment #1 Identification Number Mod- Module - Test”
Frequency, Pulse Width, or Period ule : Abnormal Frequency, Pulse Width, or
Period
Aftertreatment #1 Identification : Special Aftertreatment #1 Identification Number Mod- tus - Test”
Instruction ule : Special Instruction

Aftertreatment #2 Identification : Erratic, Inter- Aftertreatment #2 Identification Number Mod- Module - Test”
mittent, or Incorrect ule : Erratic, Intermittent, or Incorrect

Aftertreatment #2 Identification : Abnormal Aftertreatment #2 Identification Number Mod- Module - Test”
Frequency, Pulse Width, or Period ule : Abnormal Frequency, Pulse Width, or
Period
Aftertreatment #2 Identification : Special Aftertreatment #2 Identification Number Mod- tus - Test”
Instruction ule : Special Instruction

Engine Fuel Delivery Absolute Pressure : Volt- Fuel Pressure Sensor - Before Fuel Filter : tive) - Test”
age Above Normal Voltage Above Normal

Engine Fuel Delivery Absolute Pressure : Volt- Fuel Pressure Sensor - Before Fuel Filter : tive) - Test”
age Below Normal Voltage Below Normal

Engine Fuel Delivery Absolute Pressure : Data Fuel Pressure Sensor - Before Fuel Filter : Da-
Drifted Low ta Drifted Low
Engine Filtered Fuel Delivery Absolute Pres- Fuel Pressure Sensor - After Fuel Filter : Volt- tive) - Test”
sure : Voltage Above Normal age Above Normal

Engine Filtered Fuel Delivery Absolute Pres- Fuel Pressure Sensor - After Fuel Filter : Volt- tive) - Test”
sure : Voltage Below Normal age Below Normal

Engine Filtered Fuel Delivery Absolute Pres- Fuel Pressure Sensor - After Fuel Filter : Data
sure : Data Drifted Low Drifted Low
Aftertreatment #1 Intake Gas Sensor Power Engine Exhaust NOx Level Sensor Power Test”
Supply : Other Failure Mode Supply : Other Failure Mode

Aftertreatment #1 Outlet Gas Sensor Power Aftertreatment #1 Outlet #1 NOx Level Sensor Test”
Supply : Other Failure Mode Power Supply : Other Failure Mode
(continued)
56 M0070030-01
(Table 7, contd)
Aftertreatment #1 DEF Control Module Relay Aftertreatment #1 Diesel Exhaust Fluid Dosing
Control : Current Below Normal Control Module Relay : Current Below Normal

Aftertreatment #1 DEF Control Module Relay Aftertreatment #1 Diesel Exhaust Fluid Dosing
Control : Current Above Normal Control Module Relay : Current Above Normal
5966–5 3965–5 Troubleshooting, “DEF Control Module Power

Aftertreatment #1 DEF Control Module Power Aftertreatment #1 Diesel Exhaust Fluid Control - Test”
Supply : Current Below Normal Module Power Supply #1 : Current Below
Normal
Supply : Current Above Normal Module Power Supply #1 : Current Above
Normal
Aftertreatment #1 DEF Control Module #1 Aftertreatment #1 Diesel Exhaust Fluid Control - Test”
Power Supply #2 : Current Above Normal Module Power Supply #2 : Current Above
Normal
Diagnostic Trouble Codes in

Perkins Data Link (PDL) Code
Order
Table 8 lists the diagnostic trouble codes that apply to
the engine. The codes are listed in PDL code 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 8
List of Diagnostic Trouble Codes
PDL Code and Description J1939 Code and Description Troubleshooting Procedure

Cylinder #1 Injector : Current Below Normal Engine Injector Cylinder #01 : Current Below
Normal
Cylinder #1 Injector : Current Above Normal Engine Injector Cylinder #01 : Current Above
Normal
Normal
Normal
Normal
Normal
Normal
(continued)
M0070030-01 57
(Table 8, contd)
Normal
Normal
Normal
Normal
Normal
8 Volt DC Supply : Voltage Above Normal ECU 8 Volts DC Supply : Voltage Above
Normal
8 Volt DC Supply : Voltage Below Normal ECU 8 Volts DC Supply : Voltage Below
Normal
Throttle Position Sensor : Erratic, Intermittent, Accelerator Pedal Position #1 : Erratic, Inter-
or Incorrect mittent, or Incorrect

Throttle Position Sensor : Voltage Above Accelerator Pedal Position #1 : Voltage Above
Normal Normal
Throttle Position Sensor : Voltage Below Accelerator Pedal Position #1 : Voltage Below
Normal Normal
Throttle Position Sensor : Abnormal Fre- Accelerator Pedal Position #1 : Abnormal Fre-
quency, Pulse Width, or Period quency, Pulse Width, or Period

Engine Oil Pressure Sensor : Voltage Above Engine Oil Pressure : Voltage Above Normal tive) - Test”
Normal
Engine Oil Pressure Sensor : Voltage Below Engine Oil Pressure : Voltage Below Normal tive) - Test”
Normal
Crankcase Air Pressure Sensor : Voltage Engine Crankcase Pressure : Voltage Above tive) - Test”
Above Normal Normal
Crankcase Air Pressure Sensor : Voltage Be- Engine Crankcase Pressure : Voltage Below tive) - Test”
low Normal Normal
Crankcase Air Pressure Sensor : Out of Engine Crankcase Pressure : Out of - Test”
Engine Coolant Temperature Sensor : Voltage Engine Coolant Temperature : Voltage Above sive) - Test”
Above Normal Normal
(continued)
58 M0070030-01
(Table 8, contd)
Engine Coolant Temperature Sensor : Voltage Engine Coolant Temperature : Voltage Below sive) - Test”
Below Normal Normal
Electrical System Voltage : Voltage Above Battery Potential / Power Input #1 : Voltage Test”
Normal Above Normal
Electrical System Voltage : Voltage Below Battery Potential / Power Input #1 : Voltage Test”
Normal Below Normal
Ambient Air Temperature Sensor : Voltage Ambient Air Temperature : Voltage Above sive) - Test”
Above Normal Normal
Ambient Air Temperature Sensor : Voltage Be- Ambient Air Temperature : Voltage Below sive) - Test”
low Normal Normal
Fuel Temperature Sensor : Voltage Above Engine Fuel Temperature 1 : Voltage Above sive) - Test”
Normal Normal
Fuel Temperature Sensor : Voltage Below Engine Fuel Temperature 1 : Voltage Below sive) - Test”
Normal Normal
Engine Speed Sensor : Abnormal Frequency, Engine Speed : Abnormal Frequency, Pulse
Pulse Width, or Period Width, or Period

Proprietary CAN Data Link : Special Proprietary Data Link : Special Instruction tus - Test”
Instruction
SAE J1939 Data Link : Abnormal Update Rate J1939 Network #1 : Abnormal Update Rate

SAE J1939 Data Link : Special Instruction J1939 Network #1 : Special Instruction
253–2 631–2 Troubleshooting, “ECM Software - Install”

Personality Module : Erratic, Intermittent, or Calibration Module : Erratic, Intermittent, or
Incorrect Incorrect
Engine Timing Offset fault Engine Timing Sensor : Other Failure Mode

Engine Timing Calibration : Out of Calibration Engine Timing Sensor : Out of Calibration

5 Volt Sensor DC Power Supply : Voltage Sensor Supply Voltage 1 : Voltage Above
Above Normal Normal
5 Volt Sensor DC Power Supply : Voltage Be- Sensor Supply Voltage 1 : Voltage Below
low Normal Normal
Remote Shutdown Input : Voltage Above Ground-Level Shutdown Activated : Voltage Test”
Normal Above Normal
Remote Shutdown Input : Voltage Below Ground-Level Shutdown Activated : Voltage Test”
Normal Below Normal
(continued)
M0070030-01 59
(Table 8, contd)
268-2 630-2 Troubleshooting, “Programmable Parameters”
Programmed Parameter Fault : Erratic, Inter- Calibration Memory : Erratic, Intermittent, or
mittent, or Incorrect Incorrect

Fuel Pressure Sensor - Before Fuel Filter : Engine Fuel Delivery Absolute Pressure : Volt- tive) - Test”
Voltage Above Normal age Above Normal

Fuel Pressure Sensor - Before Fuel Filter : Engine Fuel Delivery Absolute Pressure : Volt- tive) - Test”
Voltage Below Normal age Below Normal

Fuel Pressure Sensor - Before Fuel Filter : Da- Engine Fuel Delivery Absolute Pressure : Data
ta Drifted Low Drifted Low
Engine Cooling Fan Solenoid : Current Below Fan Drive Bypass Command Status : Current
Normal Below Normal
Engine Cooling Fan Solenoid : Current Above Fan Drive Bypass Command Status : Current
Normal Above Normal
Secondary Engine Speed Sensor : Abnormal Engine Speed Sensor #2 : Abnormal Fre-
Frequency, Pulse Width, or Period quency, Pulse Width, or Period

Starter Motor Relay : Current Below Normal Engine Starter Motor Relay : Current Below
Normal
Starter Motor Relay : Current Above Normal Engine Starter Motor Relay : Current Above
Normal
Fuel Pressure Sensor - After Fuel Filter : Volt- Engine Filtered Fuel Delivery Absolute Pres- tive) - Test”
age Above Normal sure : Voltage Above Normal

Fuel Pressure Sensor - After Fuel Filter : Volt- Engine Filtered Fuel Delivery Absolute Pres- tive) - Test”
age Below Normal sure : Voltage Below Normal

Fuel Pressure Sensor - After Fuel Filter : Data Engine Filtered Fuel Delivery Absolute Pres-
Drifted Low sure : Data Drifted Low
Engine Fan Reversing Solenoid : Current Be- Engine Fan Reverse Actuator : Current Below Test”
low Normal Normal
Engine Fan Reversing Solenoid : Current Engine Fan Reverse Actuator : Current Above Test”
Above Normal Normal
544–2 - Troubleshooting, “Cooling Fan Speed - Test”
544–8 - Troubleshooting, “Cooling Fan Speed - Test”

Engine Cooling Fan Speed Sensor : Abnormal
Frequency, Pulse Width, or Period
582–3 107–3 Troubleshooting, “Switch Circuits - Test”

Air Filter Differential Pressure Switch : Voltage Engine Air Filter 1 Differential Pressure : Volt-
Above Normal age Above Normal
(continued)
60 M0070030-01
(Table 8, contd)
Secondary Throttle Position Sensor : Erratic, Accelerator Pedal Position #2 : Erratic, Inter-
Intermittent, or Incorrect mittent, or Incorrect

Secondary Throttle Position Sensor : Voltage Accelerator Pedal Position #2 : Voltage Above
Above Normal Normal
Secondary Throttle Position Sensor : Voltage Accelerator Pedal Position #2 : Voltage Below
Below Normal Normal
Secondary Throttle Position Sensor : Abnor- Accelerator Pedal Position #2 : Abnormal Fre-
mal Frequency, Pulse Width, or Period quency, Pulse Width, or Period
1076–5 - Troubleshooting, “Cooling Fan Control - Test”

Below Normal
1076–6 - Troubleshooting, “Cooling Fan Control - Test”
Above Normal
1551–13 4212–13 Troubleshooting, “Cooling Fan - Calibrate”
Engine Demand Fan System : Out of Fan Drive Bypass Command Status : Out of
Intake Manifold Pressure Sensor : Voltage Engine Intake Manifold #1 Absolute Pressure : tive) - Test”
Above Normal Voltage Above Normal

Intake Manifold Pressure Sensor : Voltage Be- Engine Intake Manifold #1 Absolute Pressure : tive) - Test”
low Normal Voltage Below Normal

Intake Manifold Pressure Sensor : Out of Engine Intake Manifold #1 Absolute Pressure : - Test”
Calibration Out of Calibration
Intake Manifold Pressure Sensor : Data Drifted Engine Intake Manifold #1 Absolute Pressure :
Low Data Drifted Low
Fuel Rail Pressure Sensor : Voltage Above Engine Injector Metering Rail #1 Pressure : tive) - Test”
Normal Voltage Above Normal

Fuel Rail Pressure Sensor : Voltage Below Engine Injector Metering Rail #1 Pressure : tive) - Test”
Normal Voltage Below Normal

Auxiliary Pressure Sensor : Voltage Above Auxiliary Pressure #1 : Voltage Above Normal tive) - Test”
Normal
Auxiliary Pressure Sensor : Voltage Below Auxiliary Pressure #1 : Voltage Below Normal tive) - Test”
Normal
Auxiliary Temperature Sensor : Voltage Above Auxiliary Temperature #1 : Voltage Above sive) - Test”
Normal Normal
1385–3
Auxiliary Temperature #1 : Voltage Above
Normal
(continued)
M0070030-01 61
(Table 8, contd)
Auxiliary Temperature Sensor : Voltage Below Auxiliary Temperature #1 : Voltage Below sive) - Test”
Normal Normal
1385–4
Auxiliary Temperature #1 : Voltage Below
Normal
Intake Valve Actuator #1 : Current Below Engine Intake Valve Actuator #1 : Current Be- Test”
Normal low Normal
Intake Valve Actuator #1 : Current Above Engine Intake Valve Actuator #1 : Current Test”
Normal Above Normal
Intake Valve Actuator #1 : Not Responding Engine Intake Valve Actuator #1 : Not Re- sponse - Test”
Properly sponding Properly

Normal low Normal
Normal Above Normal

Normal low Normal
Normal Above Normal

Normal low Normal
Normal Above Normal

Normal low Normal
Normal Above Normal
(continued)
62 M0070030-01
(Table 8, contd)
Normal low Normal
Normal Above Normal

Intake Valve Actuation System Oil Pressure Engine Intake Valve Actuation System Oil
Solenoid : Current Below Normal Pressure Control Valve : Current Below
Normal
Intake Valve Actuation System Oil Pressure Engine Intake Valve Actuation System Oil
Solenoid : Current Above Normal Pressure Control Valve : Current Above
Normal
Intake Valve Actuation System Oil Pressure Engine Intake Valve Actuation System Oil sponse - Test”
Solenoid : Not Responding Properly Pressure Control Valve : Not Responding
Properly

Auxiliary Pressure Sensor : Voltage Above Engine Intake Valve Actuation System Oil tive) - Test”
Normal Pressure : Voltage Above Normal

Auxiliary Pressure Sensor : Voltage Below Engine Intake Valve Actuation System Oil tive) - Test”
Normal Pressure : Voltage Below Normal
1937–2 - Troubleshooting, “Coolant Pressure Is Low”

Engine Coolant Flow Switch : Erratic, Intermit-
tent, or Incorrect

5 Volt Sensor DC Power Supply #2 : Voltage Sensor Supply Voltage 2 : Voltage Above
Above Normal Normal
5 Volt Sensor DC Power Supply #2 : Voltage Sensor Supply Voltage 2 : Voltage Below
Below Normal Normal
Engine Retarder Solenoid : Current Below Engine (Exhaust) Brake Output : Current Be-
Normal low Normal
Engine Retarder Solenoid : Current Above Engine (Exhaust) Brake Output : Current
Normal Above Normal
Engine Coolant Pump Outlet Pressure Sensor Engine Coolant Pressure : Voltage Above tive) - Test”
: Voltage Above Normal Normal

Engine Coolant Pump Outlet Pressure Sensor Engine Coolant Pressure : Voltage Below tive) - Test”
: Voltage Below Normal Normal

SAE J1939 Data Link #2 : Abnormal Update J1939 Network #2 : Abnormal Update Rate
Rate
(continued)
M0070030-01 63
(Table 8, contd)
SAE J1939 Data Link #2: Special Instruction J1939 Network #2 : Special Instruction

Ether Injection Control Solenoid : Current Be- Engine Start Enable Device 1 : Current Below
low Normal Normal
Ether Injection Control Solenoid : Current Engine Start Enable Device 1 : Current Above
Above Normal Normal
DPF #1 Intake Temperature Sensor : Voltage Aftertreatment #1 DPF Intake Temperature : tive) - Test”

DPF #1 Intake Temperature Sensor : Voltage Aftertreatment #1 DPF Intake Temperature : tive) - Test”
Below Normal Voltage Below Normal

DPF #1 Differential Pressure Sensor : Erratic, Aftertreatment #1 DPF Differential Pressure : tive) - Test”
Intermittent, or Incorrect Erratic, Intermittent, or Incorrect

DPF #1 Differential Pressure Sensor : Voltage Aftertreatment #1 DPF Differential Pressure : tive) - Test”

DPF #1 Differential Pressure Sensor : Voltage Aftertreatment #1 DPF Differential Pressure : tive) - Test”
Below Normal Voltage Below Normal

DPF #1 Differential Pressure Sensor : Out of Aftertreatment #1 DPF Differential Pressure : - Test”
Calibration Out of Calibration
ARD Fuel Pressure #1 Sensor : Voltage Above Aftertreatment #1 Fuel Pressure #1 : Voltage tive) - Test”
Normal Above Normal
ARD Fuel Pressure #1 Sensor : Voltage Below Aftertreatment #1 Fuel Pressure #1 : Voltage tive) - Test”
Normal Below Normal
ARD Fuel Pressure #1 Control : Current Below Aftertreatment #1 Fuel Pressure Control : Cur-
Normal rent Below Normal
ARD Fuel Pressure #1 Control : Current Above Aftertreatment #1 Fuel Pressure Control : Cur-
Normal rent Above Normal
Aftertreatment #1 Ignition Transformer Primary Aftertreatment #1 Ignition : Current Below
: Current Below Normal Normal
Aftertreatment #1 Ignition Transformer Primary Aftertreatment #1 Ignition : Current Above
: Current Above Normal Normal
ARD Air Pressure Control Actuator : Current Aftertreatment #1 Air Pressure Control : Cur-
Below Normal rent Below Normal
ARD Air Pressure Control Actuator : Current Aftertreatment #1 Air Pressure Control : Cur-
Above Normal rent Above Normal
(continued)
64 M0070030-01
(Table 8, contd)
2489–13 3487–13 Troubleshooting, “ARD Combustion Air Valve -
ARD Air Pressure Control Actuator : Out of Aftertreatment #1 Air Pressure Control : Out of Replace”
ARD Air Pressure Control Actuator Position Aftertreatment #1 Air Pressure Actuator Posi-
Sensor : Voltage Above Normal tion : Voltage Above Normal

ARD Air Pressure Control Actuator Position Aftertreatment #1 Air Pressure Actuator Posi-
Sensor : Voltage Below Normal tion : Voltage Below Normal

ARD Fuel Pressure #2 Sensor : Voltage Above Aftertreatment #1 Fuel Pressure #2 : Voltage tive) - Test”
Normal Above Normal
ARD Fuel Pressure #2 Sensor : Voltage Below Aftertreatment #1 Fuel Pressure #2 : Voltage tive) - Test”
Normal Below Normal
Air Inlet Temperature Sensor : Voltage Above Engine Air Inlet Temperature : Voltage Above sive) - Test”
Normal Normal
Air Inlet Temperature Sensor : Voltage Below Engine Air Inlet Temperature : Voltage Below sive) - Test”
Normal Normal
Cylinder #1 Injector Actuator #2 : Current Be- Engine Injector Cylinder #1 Actuator #2 : Cur-
low Normal rent Below Normal
Cylinder #1 Injector Actuator #2 : Current Engine Injector Cylinder #1 Actuator #2 : Cur-
(continued)
M0070030-01 65
(Table 8, contd)
Turbocharger #1 Compressor Inlet Pressure Engine Turbocharger #1 Compressor Inlet tive) - Test”
Sensor : Voltage Above Normal Pressure : Voltage Above Normal

Turbocharger #1 Compressor Inlet Pressure Engine Turbocharger #1 Compressor Inlet tive) - Test”
Sensor : Voltage Below Normal Pressure : Voltage Below Normal

Aftertreatment #1 DEF Pressure Sensor : Volt- Aftertreatment #1 DEF #1 Pressure (absolute) - Test”
age Above Normal : Voltage Above Normal

Aftertreatment #1 DEF Pressure Sensor : Volt- Aftertreatment #1 DEF #1 Pressure (absolute) - Test”
age Below Normal : Voltage Below Normal
3090–7 4334–7 Troubleshooting, “DEF Pressure Is Low”

Aftertreatment #1 SCR Dosing Reagent Pres- Aftertreatment 1 Diesel Exhaust Fluid Doser
sure Sensor : Not Responding Properly Absolute Pressure : Not Responding Properly

Aftertreatment #1 DEF Temperature #1 Sensor Aftertreatment #1 DEF Doser #1 Temperature
: Abnormal Frequency, Pulse Width, or Period : Abnormal Frequency, Pulse Width, or Period

Temperature Sensor : Voltage Above Normal Temperature : Voltage Above Normal

Temperature Sensor : Voltage Below Normal Temperature : Voltage Below Normal

Aftertreatment #1 DEF Pump Motor Speed Aftertreatment #1 DEF Pump #1 Motor Speed
Sensor : Current Below Normal : Current Below Normal
(continued)
66 M0070030-01
(Table 8, contd)
Sensor : Current Above Normal : Current Above Normal
Sensor : Abnormal Frequency, Pulse Width, or : Abnormal Frequency, Pulse Width, or Period
Period
Aftertreatment #1 DEF Tank #1 Heater Coolant Aftertreatment #1 DEF Tank Heater : Current
Diverter Solenoid : Current Below Normal Below Normal
Aftertreatment #1 DEF Tank #1 Heater Coolant Aftertreatment #1 DEF Tank Heater : Current
Diverter Solenoid : Current Above Normal Above Normal
3126–7 3363–7 Troubleshooting, “DEF Temperature Is Low”
Aftertreatment #1 SCR Catalyst Reagent Tank Aftertreatment 1 Diesel Exhaust Fluid Tank
#1 Heater Coolant Diverter Solenoid : Not Re- Heater : Not Responding Properly
sponding Properly

Aftertreatment #1 DEF Tank #1 Level Sensor : Aftertreatment #1 DEF Tank Volume #1 : Volt-
Voltage Above Normal age Above Normal

Aftertreatment #1 DEF Tank #1 Level Sensor : Aftertreatment #1 DEF Tank Volume #1 : Volt-
Voltage Below Normal age Below Normal

Aftertreatment #1 DEF Tank #1 Temperature Aftertreatment #1 DEF Tank Temperature :
Sensor : Voltage Above Normal Voltage Above Normal

Aftertreatment #1 DEF Tank #1 Temperature Aftertreatment #1 DEF Tank Temperature :
Sensor : Voltage Below Normal Voltage Below Normal

Aftertreatment #1 Ignition Transformer Secon- Aftertreatment #1 Transformer Secondary Out-
dary : Current Below Normal put : Current Below Normal

Aftertreatment #1 Fuel Injector #1 Heater : Aftertreatment #1 Fuel Injector #1 Heater Con-
Voltage Above Normal trol : Voltage Above Normal

Voltage Below Normal trol : Voltage Below Normal

Current Below Normal trol : Current Below Normal
Current Above Normal trol : Current Above Normal
Air Shutoff Relay : Current Below Normal Engine Air Shutoff Command Status : Current
Below Normal
Air Shutoff Relay : Current Above Normal Engine Air Shutoff Command Status : Current
Above Normal
(continued)
M0070030-01 67
(Table 8, contd)
Engine Charge Air Cooler #1 Outlet Tempera- Engine Charge Air Cooler Outlet Temperature sive) - Test”
ture Sensor : Voltage Above Normal : Voltage Above Normal

Engine Charge Air Cooler #1 Outlet Tempera- Engine Charge Air Cooler Outlet Temperature sive) - Test”
ture Sensor : Voltage Below Normal : Voltage Below Normal

EGR Intake Pressure Sensor : Voltage Above EGR Inlet Pressure : Voltage Above Normal tive) - Test”
Normal
EGR Intake Pressure Sensor : Voltage Below EGR Inlet Pressure : Voltage Below Normal tive) - Test”
Normal
EGR Intake Pressure Sensor : Out of EGR Inlet Pressure : Out of Calibration - Test”
Calibration
EGR Intake Pressure Sensor : Data Drifted EGR Inlet Pressure : Data Drifted Low
Low
EGR Temperature Sensor : Voltage Above EGR Temperature : Voltage Above Normal sive) - Test”
Normal
EGR Temperature Sensor : Voltage Below EGR Temperature : Voltage Below Normal sive) - Test”
Normal
EGR Differential Pressure Sensor : Voltage EGR Differential Pressure : Voltage Above tive) - Test”
Above Normal Normal
EGR Differential Pressure Sensor : Voltage EGR Differential Pressure : Voltage Below tive) - Test”
Below Normal Normal
EGR Differential Pressure Sensor : Out of EGR Differential Pressure : Out of Calibration - Test”
Calibration
ARD Fuel Pressure #2 Control Actuator : Cur- Aftertreatment #1 Fuel Pressure #2 Actuator
rent Below Normal Control : Current Below Normal
ARD Fuel Pressure #2 Control Actuator : Cur- Aftertreatment #1 Fuel Pressure #2 Actuator
rent Above Normal Control : Current Above Normal
EGR Valve Control : Current Below Normal EGR Valve Control : Current Below Normal
EGR Valve Control : Current Above Normal EGR Valve Control : Current Above Normal
ance Valve Solenoid : Current Below Normal ance Valve Actuator Control : Current Below
Normal
ance Valve Solenoid : Current Above Normal ance Valve Actuator Control : Current Above
Normal
(continued)
68 M0070030-01
(Table 8, contd)
ARD Fuel Flow Diverter Actuator : Current Be- Aftertreatment #1 Fuel Flow Diverter Valve
low Normal Control : Current Below Normal
ARD Fuel Flow Diverter Actuator : Current Aftertreatment #1 Fuel Flow Diverter Valve
Above Normal Control : Current Above Normal
Aftertreatment Fuel Pump Relay : Current Be- Aftertreatment #1 Fuel Pump Relay Control :
low Normal Current Below Normal
Aftertreatment Fuel Pump Relay : Current Aftertreatment #1 Fuel Pump Relay Control :
Above Normal Current Above Normal
DPF #1 Intake Pressure Sensor : Voltage DPF #1 Intake Pressure : Voltage Above tive) - Test”
Above Normal Normal
DPF #1 Intake Pressure Sensor : Voltage Be- DPF #1 Intake Pressure : Voltage Below tive) - Test”
low Normal Normal
DPF #1 Intake Pressure Sensor : Out of DPF #1 Intake Pressure : Out of Calibration - Test”
Calibration
DPF #1 Intake Pressure Sensor : Data Drifted DPF #1 Intake Pressure : Data Drifted Low
Low
Aftertreatment #1 Identification Number Mod- Aftertreatment #1 Identification : Erratic, Inter- Module - Test”
ule : Erratic, Intermittent, or Incorrect mittent, or Incorrect

Aftertreatment #1 Identification Number Mod- Aftertreatment #1 Identification : Abnormal Module - Test”
ule : Abnormal Frequency, Pulse Width, or Frequency, Pulse Width, or Period
Period
Aftertreatment #1 Identification Number Mod- Aftertreatment #1 Identification : Special tus - Test”
ule : Special Instruction Instruction

Aftertreatment #2 Identification Number Mod- Aftertreatment #2 Identification : Erratic, Inter- Module - Test”
ule : Erratic, Intermittent, or Incorrect mittent, or Incorrect

Aftertreatment #2 Identification Number Mod- Aftertreatment #2 Identification : Abnormal Module - Test”
ule : Abnormal Frequency, Pulse Width, or Frequency, Pulse Width, or Period
Period
Aftertreatment #2 Identification Number Mod- Aftertreatment #2 Identification : Special tus - Test”
ule : Special Instruction Instruction
3482–11 3511–11 Troubleshooting, “DEF Pump Sensor Supply -

Sensor Supply #3 : Other Failure Mode Sensor Supply Voltage 3 : Other Failure Mode Test”

Aftertreatment #1 Secondary Air Pressure Aftertreatment #1 Secondary Air Pressure : tive) - Test”
Sensor : Voltage Above Normal Voltage Above Normal

Aftertreatment #1 Secondary Air Pressure Aftertreatment #1 Secondary Air Pressure : tive) - Test”
Sensor : Voltage Below Normal Voltage Below Normal
(continued)
M0070030-01 69
(Table 8, contd)
Aftertreatment #1 Secondary Air Pressure Aftertreatment #1 Secondary Air Pressure : - Test”
Sensor : Out of Calibration Out of Calibration
Aftertreatment #1 Secondary Air Pressure Aftertreatment #1 Secondary Air Pressure :
Sensor : Data Drifted Low Data Drifted Low
Barometric Pressure Sensor : Voltage Above Barometric Pressure : Voltage Above Normal tive) - Test”
Normal
Barometric Pressure Sensor : Voltage Below Barometric Pressure : Voltage Below Normal tive) - Test”
Normal
Barometric Pressure Sensor : Data Drifted Barometric Pressure : Data Drifted Low
Low
3547–3 97–3 Troubleshooting, “Water in Fuel - Test”
Water in Fuel System Switch : Voltage Above Water In Fuel Indicator : Voltage Above
Normal Normal
Aftertreatment #1 Outlet #1 NOx Level Sensor Aftertreatment #1 Outlet NOx : Other Failure Test”
: Other Failure Mode Mode
Aftertreatment #1 Outlet #1 NOx Level Sensor Aftertreatment #1 Outlet NOx : Failure Test”
: Failure
Aftertreatment #1 Outlet #1 NOx Level Sensor Aftertreatment #1 Outlet Gas Sensor Power Test”
Power Supply : Other Failure Mode Supply : Other Failure Mode

Engine Exhaust NOx Level Sensor Power Aftertreatment #1 Intake Gas Sensor Power Test”
Supply : Other Failure Mode Supply : Other Failure Mode

Aftertreatment #1 Intake NOx Level Sensor : Aftertreatment #1 Intake NOx : Other Failure Test”
Other Failure Mode Mode
Aftertreatment #1 Intake NOx Level Sensor : Aftertreatment #1 Intake NOx : Failure Test”
Failure
Auxiliary Temperature Sensor #2 : Voltage Auxiliary Temperature #2 : Voltage Above sive) - Test”
Above Normal Normal
Auxiliary Temperature Sensor #2 : Voltage Be- Auxiliary Temperature #2 : Voltage Below sive) - Test”
low Normal Normal
Aftertreatment #1 Diesel Exhaust Fluid Con- Aftertreatment #1 DEF Controller : Voltage Test”
troller : Voltage Above Normal Above Normal

Aftertreatment #1 Diesel Exhaust Fluid Con- Aftertreatment #1 DEF Controller : Voltage Be- Test”
troller : Voltage Below Normal low Normal

Aftertreatment #1 Diesel Exhaust Fluid Con- Aftertreatment #1 DEF Controller : Abnormal
troller : Abnormal Update Rate Update Rate
(continued)
70 M0070030-01
(Table 8, contd)
Aftertreatment #1 Diesel Exhaust Fluid Con- Aftertreatment #1 DEF Controller : Failure Test”
troller : Failure
Aftertreatment #1 Diesel Exhaust Fluid Dosing Aftertreatment #1 DEF Dosing Unit : Current
Valve Actuator : Current Below Normal Below Normal
Aftertreatment #1 Diesel Exhaust Fluid Dosing Aftertreatment #1 DEF Dosing Unit : Current
Valve Actuator : Current Above Normal Above Normal
Aftertreatment #1 Diesel Exhaust Fluid Dosing Catalyst Dosing Unit : Not Responding Respond”
Valve Actuator : Not Responding Properly Properly

Aftertreatment #1 Diesel Exhaust Fluid Dosing Catalyst Dosing Unit : Other Failure Mode Respond”
Valve Actuator : Other Failure Mode
Aftertreatment #1 Diesel Exhaust Fluid Dosing Catalyst Dosing Unit : Special Instruction Respond”
Valve Actuator : Special Instruction

Aftertreatment #1 Diesel Exhaust Fluid Line Aftertreatment #1 DEF Line Heater Relay :
Heater Relay : Current Below Normal Current Below Normal

Aftertreatment #1 Diesel Exhaust Fluid Line Aftertreatment #1 DEF Line Heater Relay :
Heater Relay : Current Above Normal Current Above Normal

Aftertreatment #1 Diesel Exhaust Fluid Dosing Aftertreatment #1 DEF Control Module Relay
Control Module Relay : Current Below Normal Control : Current Below Normal

Aftertreatment #1 Diesel Exhaust Fluid Dosing Aftertreatment #1 DEF Control Module Relay
Control Module Relay : Current Above Normal Control : Current Above Normal

Aftertreatment #1 Diesel Exhaust Fluid Return Aftertreatment #1 DEF Return Valve : Not Re-
Valve Solenoid : Not Responding Properly sponding Properly

Supply : Current Below Normal Module Power Supply #1 : Current Below
Normal
Aftertreatment #1 Diesel Exhaust Fluid Return Aftertreatment #1 DEF Return Valve : Current
Valve Solenoid : Current Below Normal Below Normal
Aftertreatment #1 Diesel Exhaust Fluid Return Aftertreatment #1 DEF Return Valve : Current
Valve Solenoid : Current Above Normal Above Normal
Aftertreatment #1 Diesel Exhaust Fluid Control Aftertreatment #1 DEF Control Module Power - Test”
Module Power Supply #1 : Current Below Supply : Current Below Normal
Normal
Aftertreatment #1 Diesel Exhaust Fluid Control Aftertreatment #1 DEF Control Module Power - Test”
Module Power Supply #1 : Current Above Supply : Current Above Normal
Normal
(continued)
M0070030-01 71
(Table 8, contd)
Aftertreatment #1 Diesel Exhaust Fluid Control Aftertreatment #1 DEF Control Module #1 - Test”
Module Power Supply #2 : Current Above Power Supply #2 : Current Above Normal
Normal
SAE J1939 Data Link #3 : Abnormal Update J1939 Network #3 : Abnormal Update Rate
Rate
SAE J1939 Data Link #3: Special Instruction J1939 Network #3 : Special Instruction
72 M0070030-01
Event Codes
Event Codes
i06636086
Event Codes
Event codes are generated when abnormal operating

conditions exist. A further explanation of event codes
and the engine monitoring system are described after
Table 10 .
Event Codes in J1939 Code Order

Table 9 is a list of the event codes for the engine. The
event codes are listed in order of J1939 codes. The
event codes are cross-referenced with the
appropriate procedure that can be used to
troubleshoot the code.
Table 9
Event Codes
J1939 Code and Description PDL Code and Description Troubleshooting Procedure
- E265 (1) Troubleshooting, “Engine Shutdown

User Defined Shutdown Occurrence”
- E563 (3) Troubleshooting, “Coolant Pressure Is Low”
Low Engine Coolant Flow
- E994 (2) Troubleshooting, “Low Crankcase Pressure”

Low Crankcase Pressure
97–15 E232 (1) Troubleshooting, “Fuel System Water Separa-
Water in Fuel Indicator : High - least severe (1) High Fuel/Water Separator Water Level tor Has Water”
97–16 E232 (2) Troubleshooting, “Fuel System Water Separa-

Water in Fuel Indicator : High - moderate se- High Fuel/Water Separator Water Level tor Has Water”
verity (2)
100–1 E360 (3) Troubleshooting, “Oil Pressure Is Low”

Engine Oil Pressure : Low - most severe (3) Low Engine Oil Pressure

Engine Oil Pressure : Low - least severe (1) Low Engine Oil Pressure

Engine Oil Pressure : Low - moderate severity Low Engine Oil Pressure
(2)
101–15 E1036 (1) Troubleshooting, “Crankcase Pressure Is

Engine Crankcase Pressure : High - least se- High Crankcase Pressure High”
vere (1)
101–16 E1036 (2) Troubleshooting, “Crankcase Pressure Is

Engine Crankcase Pressure : High - moderate High Crankcase Pressure High”
severity (2)
(continued)
M0070030-01 73
Event Codes
(Table 9, contd)
102–1 E1045 (3) Troubleshooting, “Intake Manifold Air Pressure
Engine Intake Manifold #1 Pressure : Low - Low Intake Manifold Pressure Is Low”
most severe (3)

Engine Intake Manifold #1 Pressure : Low - Low Intake Manifold Pressure Is Low”
moderate severity (2)
105–0 E539 (3) Troubleshooting, “Intake Manifold Air Temper-

Engine Intake Manifold #1 Temperature : High High Intake Manifold Air Temperature ature Is High”
- most severe (3)

- least severe (1)

- moderate severity (2)
107–15 E583 (1) Troubleshooting, “Inlet Air Is Restricted”

Engine Air Filter 1 Differential Pressure : High - High Air Inlet #1 Differential Pressure
least severe (1)
107–16 E583 (2) Troubleshooting, “Inlet Air Is Restricted”

Engine Air Filter 1 Differential Pressure : High - High Air Inlet #1 Differential Pressure
109–1 E2112 (3) Troubleshooting, “Coolant Pressure Is Low”

Engine Coolant Pressure : Low - most severe Low Engine Coolant Pressure
(3)

Engine Coolant Pressure : Low - least severe Low Engine Coolant Pressure
(1)

Engine Coolant Pressure - Low - moderate se- Low Engine Coolant Pressure
verity (2)
110–0 E361 (3) Troubleshooting, “Coolant Temperature Is

Engine Coolant Temperature : High - most se- High Engine Coolant Temperature High”
vere (3)

Engine Coolant Temperature : High - least se- High Engine Coolant Temperature High”
vere (1)

Engine Coolant Temperature : High - moderate High Engine Coolant Temperature High”
severity (2)

Engine Coolant Temperature : Low - least se- Low Coolant Temperature Low”
vere (1)
111–1 E2143 (3) Troubleshooting, “Coolant Level Is Low”

Engine Coolant Level Low - most severe (3) Low Engine Coolant Level

Engine Coolant Level - Low - least severe (1) Low Engine Coolant Level

Engine Coolant Level Low - moderate severity Low Engine Coolant Level
(2)
(continued)
74 M0070030-01
Event Codes
(Table 9, contd)
168–31 E441 (1) Troubleshooting, “Idle Speed Is High”
Battery Potential / Power Input #1 Idle Elevated to Increase Battery Voltage
174–0 E363 (3) Troubleshooting, “Fuel Temperature Is High”

Engine Fuel Temperature 1 : High - most se- High Fuel Supply Temperature
vere (3)

Engine Fuel Temperature 1 : High - least se- High Fuel Supply Temperature
vere (1)

Engine Fuel Temperature 1 : High - moderate High Fuel Supply Temperature
severity (2)
175–0 E197 (3) Troubleshooting, “Oil Temperature Is High”

Engine Oil Temperature 1 : High - most severe High Engine Oil Temperature
(3)

Engine Oil Temperature 1 : High - least severe High Engine Oil Temperature
(1)

Engine Oil Temperature 1 : High - moderate High Engine Oil Temperature
severity (2)
190–0 E362 (3) Troubleshooting, “Engine Overspeeds”

Engine Speed : High - most severe (3) Engine Overspeed
190–15 E362 (1) Troubleshooting, “Engine Overspeeds”

Engine Speed : High - least severe (1) Engine Overspeed
411–15 E1094 (1) Troubleshooting, “NOx Reduction System

EGR Differential Pressure : High - least severe High EGR Differential Pressure (NRS) - Test”
(1)

EGR Differential Pressure : Low - least severe Low EGR Differential Pressure (NRS) - Test”
(1)
412–15 E1092 (1) Troubleshooting, “NRS Exhaust Gas Tempera-

EGR Temperature : High - least severe (1) High EGR Temperature ture Is High”
412–16 E1092 (2) Troubleshooting, “NRS Exhaust Gas Tempera-

EGR Temperature : High - moderate severity High EGR Temperature ture Is High”
(2)
593–31 E1171 (1) Troubleshooting, “Engine Shutdown While

Engine Idle Shutdown has Shutdown Engine Engine Idle Shutdown Occurred Idling”

Engine Idle Shutdown Driver Alert Mode Engine Idle Shutdown Pending Idling”

Engine Idle Shutdown Driver Alert Mode Engine Idle Shutdown Pending Idling”
1639–17 E1363 (1) Troubleshooting, “Cooling Fan Speed - Test”

Fan Speed : Low - least severe (1) Low Engine Cooling Fan Speed
1664–31 E225 (3) Troubleshooting, “Engine Overcrank

Engine Automatic Start Failed Engine Overcrank Occurrence”
1761–1 E954 (3) Troubleshooting, “DEF Tank Level Is Low”

Afterteatment 1 Diesel Exhaust Fluid Tank Low Aftertreatment #1 SCR Catalyst Reagent
Level : Low - most severe (3) Tank #1 Level
(continued)
M0070030-01 75
Event Codes
(Table 9, contd)
Level : Low - least severe (1) Tank #1 Level

Level : Low - moderate severity (2)

Engine Charge Air Cooler Outlet Temperature Low Engine Charge Air Cooler #1 Outlet Is Low”
: Low - most severe (3) Temperature

EGR Mass Flow Rate : High - least severe (1) High EGR Mass Flow Rate (NRS) - Test”

EGR Mass Flow Rate : Low - least severe (1) Low EGR Mass Flow Rate (NRS) - Test”
2948–7 E1101 (2) Troubleshooting, “Variable Valve Actuator Re-

Engine Intake Valve Actuation System Oil Intake Valve Actuation System Oil Pressure #1 sponse - Test”
Pressure : Not Responding Properly Not Responding to Command
2948–17 E488 (2) Troubleshooting, “Variable Valve Actuator Re-

Engine Intake Valve Actuation System Oil Low Intake Valve Actuation Pressure sponse - Test”
Pressure : Low - least severe (1)
3031–7 E1441 (2) Troubleshooting, “DEF Temperature Is Low”

Aftertreatment 1 Diesel Exhaust Fluid Tank Aftertreatment #1 Diesel Exhaust Fluid Tank
Temperature : Not Responding Properly Temperature Not Responding Properly
3031–16 E960 (2) Troubleshooting, “DEF Tank Temperature Is

Aftertreatment 1 Diesel Exhaust Fluid Tank High Aftertreatment #1 SCR Catalyst Reagent High”
Temperature : High - moderate severity Tank #1 Temperature

Aftertreatment 1 Diesel Exhaust Fluid Tank Low Aftertreatment #1 SCR Catalyst Reagent
Temperature : Low - moderate severity (2) Tank #1 Temperature
3216–7 E1431 (2) Troubleshooting, “NOx Sensor - Test”

Aftertreatment #1 Intake NOx : Not Respond- Invalid Aftertreatment #1 Intake NOx Level #1
ing Properly
3217–16 E1407 (2) Troubleshooting, “Clean Emissions Module

Aftertreatment #1 Intake O2 : High - moderate High Aftertreatment #1 Intake O2 Has High Oxygen Level”
severity (2) Concentration
3226–7 E1432 (2) Troubleshooting, “NOx Sensor - Test”

Aftertreatment #1 Outlet NOx : Not Respond- Invalid Aftertreatment #1 Outlet NOx Level #1
ing Properly
3227–16 E1408 (2) Troubleshooting, “Clean Emissions Module

Aftertreatment #1 Outlet O2 : High - moderate High Aftertreatment #1 Outlet O2 Has High Oxygen Level”
severity Concentration
3242–15 E1008 (1) Troubleshooting, “Diesel Particulate Filter

Particulate Trap Intake Gas Temperature : High DPF #1 Intake Temperature Temperature Is High”
High - least severe (1)
3242–16 E1008 (2) Troubleshooting, “Diesel Particulate Filter

Particulate Trap Intake Gas Temperature : High DPF #1 Intake Temperature Temperature Is High”
High - moderate severity (2)
3242–18 E1014 (2) Troubleshooting, “Diesel Particulate Tempera-

Particulate Trap Intake Gas Temperature : Low Low DPF #1 Intake Temperature ture Is Low”
(continued)
76 M0070030-01
Event Codes
(Table 9, contd)
3362–14 E114 (1) Troubleshooting, “DEF Does Not Purge”
Aftertreatment 1 Diesel Exhaust Fluid Dosing Aftertreatment #1 Diesel Exhaust Fluid Dosing
Unit Input Lines Unit Input Lines Not Purged
3473–31 E1025 (2) Troubleshooting, “ARD Failed to Ignite”

Aftertreatment #1 Failed to Ignite Aftertreatment #1 Failed to Ignite
3474–14 E1026 (1) Troubleshooting, “ARD Loss of Combustion”

Aftertreatment #1 Loss of Combustion : Spe- Aftertreatment #1 Loss of Combustion
cial Instruction
3474–31 E1026 (2) Troubleshooting, “ARD Loss of Combustion”
Aftertreatment #1 Loss of Combustion Aftertreatment #1 Loss of Combustion
3480–15 E1050 (1) Troubleshooting, “ARD Fuel Pressure Is High”
Aftertreatment #1 Fuel Pressure #1 : High - High Aftertreatment #1 Fuel Pressure #1
least severe (1)

3480–17 E1052 (1) Troubleshooting, “ARD Fuel Pressure Is Low”

Aftertreatment #1 Fuel Pressure #1 : Low - Low Aftertreatment #1 Fuel Pressure #1
least severe (1)

3483–11 E1305 (1) Troubleshooting, “ARD Is Disabled”

Aftertreatment #1 Regeneration Status : Other Initial Assembly Aftertreatment #1 Procedure
Failure Mode Required
3487–7 E1041 (1) Troubleshooting, “ARD Combustion Air - Test”

Aftertreatment #1 Air Pressure Control : Not ARD Air Pressure Control Actuator Not Re-
Responding Properly sponding to Command
3516–16 E1365 (2) Troubleshooting, “NOx Conversion Is Low”

Catalyst Reagent Concentration : High - mod- High Aftertreatment #1 DEF Concentration
erate severity

Catalyst Reagent Concentration : Low - mod- Low Aftertreatment #1 DEF Concentration
erate severity (2)

Aftertreatment #1 Regeneration Manually ARD Manually Disabled
Disabled
3609–15 E1156 (1) Troubleshooting, “Diesel Particulate Filter Has
DPF #1 Intake Pressure : High - least severe High DPF #1 Intake Pressure High Inlet Pressure”
(1)

DPF #1 Intake Pressure : Low - least severe Low DPF #1 Intake Pressure Low Inlet Pressure”
(1)

DPF #1 Intake Pressure : Low - moderate se- Low DPF #1 Intake Pressure Low Inlet Pressure”
verity (2)
3667–2 E2088 (1) Troubleshooting, “Air Shutoff - Test”

Engine Air Shutoff Status : Erratic, Intermittent, Air Intake Shutoff Detection Circuit Detected
or Incorrect but Not Installed
3667–31 E2087 (3) Troubleshooting, “Air Shutoff - Test”
Engine Air Shutoff Status Air Intake Shutoff Closed
(continued)
M0070030-01 77
Event Codes
(Table 9, contd)
Particulate Trap Active Regeneration Inhibited DPF Active Regeneration Inhibited Due to In-
Due to Inhibit Switch hibit Switch
3711–31 E593 (2) Troubleshooting, “ARD Temperature Is Low”
Particulate Trap Active Regeneration Inhibited Aftertreatment Insufficient Temperature to
Due to Low Exhaust Gas Temperature Complete Regeneration

DPF Active Regeneration Inhibited Due to Sys- Aftertreatment Regeneration Cannot Start Due
tem Fault Active : High - least severe to System Fault
3714–31 E992 (3) Troubleshooting, “Diesel Particulate Filter Col-

Particulate Trap Active Regeneration Inhibited DPF Active Regeneration Inhibited Due to lects Excessive Soot”
Due to Temporary System Lockout Temporary System Lockout

Particulate Trap Active Regeneration Inhibited DPF Active Regeneration Inhibited Due to Per- lects Excessive Soot”
Due to Permanent System Lockout manent System Lockout

DPF Active Regeneration Inhibited Due to En- Aftertreatment Regeneration Cannot Start Due
gine Not Warmed Up : High - least severe (1) to Low Engine Temperature

DPF Active Regeneration Inhibited Due to En- Aftertreatment Regeneration Cannot Start Due
gine Not Warmed Up to Low Engine Temperature

Particulate Trap #1 Soot Load Percent : High - High DPF #1 Soot Loading lects Excessive Soot”
most severe (3)

Particulate Trap #1 Soot Load Percent : High - High DPF #1 Soot Loading lects Excessive Soot”

Particulate Trap #1 Ash Load Percent : High - High DPF #1 Ash Loading High Ash Load”
least severe (1)

Particulate Trap #1 Ash Load Percent : High - High DPF #1 Ash Loading High Ash Load”

DPF #1 Conditions Not Met for Active Regen- Aftertreatment Regeneration Cannot Start Due
eration : High - least severe (1) to Conditions Not Met

DPF #1 Conditions Not Met for Active Regen- DPF #1 Conditions Not Met for Active
eration : Low - least severe (1) Regeneration

DPF #1 Conditions Not Met for Active Regen- DPF #1 Conditions Not Met for Active
eration : Low - moderate severity (2) Regeneration

DPF #1 Conditions Not Met for Active DPF #1 Conditions Not Met for Active
Regeneration Regeneration
3837–17 E1170 (1) Troubleshooting, “ARD Combustion Supply Air

Aftertreatment 1 Secondary Air Pressure : Low Low Aftertreatment #1 Secondary Air Pressure Pressure Is Low”
- least severe
least severe (1
(continued)
78 M0070030-01
Event Codes
(Table 9, contd)

least severe (1)

4215–31 E678 (1) Troubleshooting, “Shutdown (Ground Level) -

Ground-Level Shutdown Activated Ground Level Shutdown Test”
4334–16 E930 (2) Troubleshooting, “DEF Pressure Is High”
Aftertreatment 1 Diesel Exhaust Fluid Doser High Aftertreatment #1 SCR Dosing Reagent
Absolute Pressure : High - moderate severity Pressure
4334–18 E931 (2) Troubleshooting, “DEF Pressure Is Low”

Aftertreatment 1 Diesel Exhaust Fluid Doser Low Aftertreatment #1 SCR Dosing Reagent
Absolute Pressure - Low - moderate severity Pressure
4360–16 E946 (2) Troubleshooting, “SCR Catalyst Inlet Tempera-

Aftertreatment #1 SCR Catalyst Intake Gas High Aftertreatment #1 SCR Catalyst Intake ture Sensor - Test”
Temperature : High - moderate severity (2) Gas Temperature

Aftertreatment #1 SCR Catalyst Intake Gas Low Aftertreatment #1 SCR Catalyst Intake ture Sensor - Test”
Temperature : Low - least severe (1) Gas Temperature

Aftertreatment #1 SCR Catalyst Intake Gas Low Aftertreatment #1 SCR Catalyst Intake ture Sensor - Test”
Temperature : Low - moderate severity (2) Gas Temperature

Aftertreatment #1 SCR Catalyst Conversion Invalid Aftertreatment #1 SCR Conversion
Efficiency : Erratic, Intermittent, or Incorrect Efficiency

Aftertreatment #1 SCR Catalyst Conversion Low Aftertreatment #1 SCR Catalyst Conver-
Efficiency : Low - moderate severity (2) sion Efficiency
5246–0 E1389 (3) Troubleshooting, “SCR Warning System

Aftertreatment SCR Operator Inducement Se- Aftertreatment #1 SCR Operator Inducement Problem”
verity : High - most severe (3)

verity : High - least severe (1)

verity : High - moderate severity (2)
5272–31 E268 (3) Troubleshooting, “Engine Shutdown

Unexpected Engine Shutdown Unexpected Engine Shutdown Occurrence”

Unexpected Engine Shutdown Engine Stall Condition Occurrence”
(continued)
M0070030-01 79
Event Codes
(Table 9, contd)
5392–31 E1370 (2) Troubleshooting, “DEF Pressure Is Low”
Aftertreatment Diesel Exhaust Fluid Dosing Aftertreatment #1 Diesel Exhaust Fluid Dosing
Unit Loss of Prime Unit Loss of Prime
5480–16 E1430 (2) Troubleshooting, “DEF Control Module Tem-
Aftertreatment 1 Diesel Exhaust Fluid Control- High Aftertreatment #1 Diesel Exhaust Fluid perature Is High”
ler Temperature : High - moderate severity (2) Controller Temperature
5580–16 E096 (2) Troubleshooting, “Fuel Pressure Is High”

Engine Filtered Fuel Delivery Absolute Pres- High Fuel Pressure
sure : High - moderate severity (2)
5580–17 E198 (1) Troubleshooting, “Fuel Pressure Is Low”

Engine Filtered Fuel Delivery Absolute Pres- Low Fuel Pressure
sure : Low - least severe (1)
5580–18 E198 (2) Troubleshooting, “Fuel Pressure Is Low”

Engine Filtered Fuel Delivery Absolute Pres- Low Fuel Pressure
sure : Low - moderate severity (2)
5584–15 E390 (1) Troubleshooting, “Fuel Filter Is Restricted”

Engine Fuel Filter Degradation : High - least Fuel Filter Restriction
severe (1)
5584–16 E390 (2) Troubleshooting, “Fuel Filter Is Restricted”

Engine Fuel Filter Degradation : High - moder- Fuel Filter Restriction
ate severity (2)
5588–14 E1132 (2) Troubleshooting, “Data Link Configuration Sta-

Proprietary Network #2 : Special Instruction Inconsistent Configuration Detected tus - Test”

Aftertreatment 1 Diesel Exhaust Fluid Dosing Aftertreatment #1 SCR Dosing Pump Temper-
Unit Heater Temperature : Not Responding ature Not Responding
Properly
6322–31 E1465 (1) Troubleshooting, “Desulfation Is Frequent”

Aftertreatment #1 SCR Desulfation Too Aftertreatment #1 SCR Desulfation Too
Frequent Frequent

Operator Shutdown With High Exhaust Operator Forced Shutdown with High Exhaust Occurrence”
Temperature Temperature
Event Codes in Perkins Data Link

(PDL) Code Order
Table 10 is a list of the event codes for the engine.
The event codes are listed in order of PDL codes.
The event codes are cross-referenced with the
appropriate procedure that can be used to
troubleshoot the code.
Table 10
Event Codes
PDL Code and Description J1939 Code and Description Troubleshooting Procedure
E096 (2) 5580–16 Troubleshooting, “Fuel Pressure Is High”

High Fuel Pressure Engine Filtered Fuel Delivery Absolute Pres-
sure : High - moderate severity (2)
E114 (1) 3362–14 Troubleshooting, “DEF Does Not Purge”

Aftertreatment #1 Diesel Exhaust Fluid Dosing Aftertreatment 1 Diesel Exhaust Fluid Dosing
Unit Input Lines Not Purged Unit Input Lines
(continued)
80 M0070030-01
Event Codes
(Table 10, contd)

E197 (1) 175–15 Troubleshooting, “Oil Temperature Is High”
High Engine Oil Temperature Engine Oil Temperature 1 : High - least severe
(1)

High Engine Oil Temperature Engine Oil Temperature 1 : High - moderate
severity (2)

High Engine Oil Temperature Engine Oil Temperature 1 : High - most severe
(3)
E198 (1) 5580–17 Troubleshooting, “Fuel Pressure Is Low”

Low Fuel Pressure Engine Filtered Fuel Delivery Absolute Pres-
sure : Low - least severe (1)
E198 (2) 5580–18 Troubleshooting, “Fuel Pressure Is Low”

Low Fuel Pressure Engine Filtered Fuel Delivery Absolute Pres-
sure : Low - moderate severity (2)
E199 (1) 110–17 Troubleshooting, “Coolant Temperature Is

Low Coolant Temperature Engine Coolant Temperature : Low - least se- Low”
vere (1)
E225 (3) 1664–31 Troubleshooting, “Engine Overcrank

Engine Overcrank Engine Automatic Start Failed Occurrence”
E232 (1) 97–15 Troubleshooting, “Fuel System Water Separa-

High Fuel/Water Separator Water Level Water in Fuel Indicator : High - least severe (1) tor Has Water”
E232 (2) 97–16 Troubleshooting, “Fuel System Water Separa-

High Fuel/Water Separator Water Level Water in Fuel Indicator : High - moderate se- tor Has Water”
verity (2)
E265 (1) - Troubleshooting, “Engine Shutdown

E268 (3) 5272–31 Troubleshooting, “Engine Shutdown
Unexpected Engine Shutdown Unexpected Engine Shutdown Occurrence”
E360 (1) 100–17 Troubleshooting, “Oil Pressure Is Low”

Low Engine Oil Pressure Engine Oil Pressure : Low - least severe (1)

Low Engine Oil Pressure Engine Oil Pressure : Low - moderate severity
(2)

Low Engine Oil Pressure Engine Oil Pressure : Low - most severe (3)

High Engine Coolant Temperature Engine Coolant Temperature : High - least se- High”
vere (1)

High Engine Coolant Temperature Engine Coolant Temperature : High - moderate High”
severity (2)

High Engine Coolant Temperature Engine Coolant Temperature : High - most se- High”
vere (3)
(continued)
M0070030-01 81
Event Codes
(Table 10, contd)

E362 (3) 190–0 Troubleshooting, “Engine Overspeeds”
Engine Overspeed Engine Speed : High - most severe (3)
E362 (1) 190–15 Troubleshooting, “Engine Overspeeds”

Engine Overspeed Engine Speed : High - least severe (1)
E362 (3) 190–0 Troubleshooting, “Fuel Filter Is Restricted”

Engine Overspeed Engine Speed : High - most severe (3)
E363 (1) 174–15 Troubleshooting, “Fuel Temperature Is High”

High Fuel Supply Temperature Engine Fuel Temperature 1 : High - least se-
vere (1)

High Fuel Supply Temperature Engine Fuel Temperature 1 : High - moderate
severity (2)

High Fuel Supply Temperature Engine Fuel Temperature 1 : High - most se-
vere (3)
E390 (2) 5584–16 Troubleshooting, “Fuel Filter Is Restricted”

Fuel Filter Restriction Engine Fuel Filter Degradation : High - moder-
ate severity (2)
E441 (1) 168–31 Troubleshooting, “Idle Speed Is High”

Idle Elevated to Increase Battery Voltage Battery Potential / Power Input #1
E488 (2) 2948–17 Troubleshooting, “Variable Valve Actuator Re-

Low Intake Valve Actuation Pressure Engine Intake Valve Actuation System Oil sponse - Test”
E539 (3) 105–0 Troubleshooting, “Intake Manifold Air Temper-

High Intake Manifold Air Temperature Engine Intake Manifold #1 Temperature : High ature Is High”
- most severe (3)

- least severe (1)

E563 (3) - Troubleshooting, “Coolant Pressure Is Low”

Low Engine Coolant Flow
E583 (1) 107–15 Troubleshooting, “Inlet Air Is Restricted”

High Air Inlet #1 Differential Pressure Engine Air Filter 1 Differential Pressure : High -
least severe (1)
E583 (2) 107–16 Troubleshooting, “Inlet Air Is Restricted”

High Air Inlet #1 Differential Pressure Engine Air Filter 1 Differential Pressure : High -
E593 (2) 3711–31 Troubleshooting, “ARD Temperature Is Low”

Aftertreatment Insufficient Temperature to Particulate Trap Active Regeneration Inhibited
Complete Regeneration Due to Low Exhaust Gas Temperature
E678 (1) 4215–31 Troubleshooting, “Shutdown (Ground Level) -

Ground Level Shutdown Ground-Level Shutdown Activated Test”
(continued)
82 M0070030-01
Event Codes
(Table 10, contd)

E930 (2) 4334–16 Troubleshooting, “DEF Pressure Is High”
High Aftertreatment #1 SCR Dosing Reagent Aftertreatment 1 Diesel Exhaust Fluid Doser
Pressure Absolute Pressure : High - moderate severity
E931 (2) 4334–18 Troubleshooting, “DEF Pressure Is Low”

Low Aftertreatment #1 SCR Dosing Reagent Aftertreatment 1 Diesel Exhaust Fluid Doser
Pressure Absolute Pressure - Low - moderate severity
E946 (2) 4360–16 Troubleshooting, “SCR Catalyst Inlet Tempera-

High Aftertreatment #1 SCR Catalyst Intake Aftertreatment #1 SCR Catalyst Intake Gas ture Sensor - Test”
Gas Temperature Temperature : High - moderate severity (2)

Low Aftertreatment #1 SCR Catalyst Intake Aftertreatment #1 SCR Catalyst Intake Gas ture Sensor - Test”
Gas Temperature Temperature : Low - least severe (1)

Low Aftertreatment #1 SCR Catalyst Intake Aftertreatment #1 SCR Catalyst Intake Gas ture Sensor - Test”
Gas Temperature Temperature : Low - moderate severity (2)
E954 (1) 1761–17 Troubleshooting, “DEF Tank Level Is Low”

Low Aftertreatment #1 SCR Catalyst Reagent Afterteatment 1 Diesel Exhaust Fluid Tank
Tank #1 Level Level : Low - least severe (1)

Level : Low - moderate severity (2)

Tank #1 Level Level : Low - most severe (3)
E960 (2) 3031–16 Troubleshooting, “DEF Tank Temperature Is

High Aftertreatment #1 SCR Catalyst Reagent Aftertreatment 1 Diesel Exhaust Fluid Tank High”
Tank #1 Temperature Temperature : High - moderate severity
E991 (3) 3715–31 Troubleshooting, “Diesel Particulate Filter Col-

DPF Active Regeneration Inhibited Due to Per- Particulate Trap Active Regeneration Inhibited lects Excessive Soot”
manent System Lockout Due to Permanent System Lockout

DPF Active Regeneration Inhibited Due to Particulate Trap Active Regeneration Inhibited lects Excessive Soot”
Temporary System Lockout Due to Temporary System Lockout
E993 (2) 3703–31 Troubleshooting, “ARD Is Disabled”

DPF Active Regeneration Inhibited Due to In- Particulate Trap Active Regeneration Inhibited
hibit Switch Due to Inhibit Switch
E994 (2) - Troubleshooting, “Low Crankcase Pressure”
Low Crankcase Pressure
High DPF #1 Soot Loading Particulate Trap #1 Soot Load Percent : High - lects Excessive Soot”

High DPF #1 Soot Loading Particulate Trap #1 Soot Load Percent : High - lects Excessive Soot”
most severe (3)
E997 (1) 3720–15 Troubleshooting, “Diesel Particulate Filter Has

High DPF #1 Ash Loading Particulate Trap #1 Ash Load Percent : High - High Ash Load”
least severe (1)

High DPF #1 Ash Loading Particulate Trap #1 Ash Load Percent : High - High Ash Load”
(continued)
M0070030-01 83
Event Codes
(Table 10, contd)

E1008 (1) 3242–15 Troubleshooting, “Diesel Particulate Filter
High DPF #1 Intake Temperature Particulate Trap Intake Gas Temperature : Temperature Is High”
High - least severe (1)
E1008 (2) 3242–16 Troubleshooting, “Diesel Particulate Filter

High DPF #1 Intake Temperature Particulate Trap Intake Gas Temperature : Temperature Is High”
E1014 (2) 3242–18 Troubleshooting, “Diesel Particulate Tempera-

Low DPF #1 Intake Temperature Particulate Trap Intake Gas Temperature : Low ture Is Low”
E1025 (2) 3473–31 Troubleshooting, “ARD Failed to Ignite”

Aftertreatment #1 Failed to Ignite Aftertreatment #1 Failed to Ignite
E1026 (1) 3474–14 Troubleshooting, “ARD Loss of Combustion”

Aftertreatment #1 Loss of Combustion Aftertreatment #1 Loss of Combustion : Spe-
cial Instruction
E1026 (2) 3474–31 Troubleshooting, “ARD Loss of Combustion”
Aftertreatment #1 Loss of Combustion Aftertreatment #1 Loss of Combustion
E1036 (1) 101–15 Troubleshooting, “Crankcase Pressure Is
High Crankcase Pressure Engine Crankcase Pressure : High - least se- High”
vere (1)
E1036 (2) 101–16 Troubleshooting, “Crankcase Pressure Is

High Crankcase Pressure Engine Crankcase Pressure : High - moderate High”
severity (2)

ARD Manually Disabled Aftertreatment #1 Regeneration Manually
Disabled
E1041 (1) 3487–7 Troubleshooting, “ARD Combustion Air - Test”
ARD Air Pressure Control Actuator Not Re- Aftertreatment #1 Air Pressure Control : Not
sponding to Command Responding Properly
E1045 (2) 102–18 Troubleshooting, “Intake Manifold Air Pressure

Low Intake Manifold Pressure Engine Intake Manifold #1 Pressure : Low - Is Low”

Low Intake Manifold Pressure Engine Intake Manifold #1 Pressure : Low - Is Low”
most severe (3)
E1050 (1) 3480–15 Troubleshooting, “ARD Fuel Pressure Is High”

High Aftertreatment #1 Fuel Pressure #1 Aftertreatment #1 Fuel Pressure #1 : High -
least severe (1)


least severe (1

E1052 (1) 3480–17 Troubleshooting, “ARD Fuel Pressure Is Low”

Low Aftertreatment #1 Fuel Pressure #1 Aftertreatment #1 Fuel Pressure #1 : Low -
least severe (1)
(continued)
84 M0070030-01
Event Codes
(Table 10, contd)


least severe (1)

E1092 (1) 412–15 Troubleshooting, “NRS Exhaust Gas Tempera-

High EGR Temperature EGR Temperature : High - least severe (1) ture Is High”
E1092 (2) 412–16 Troubleshooting, “NRS Exhaust Gas Tempera-

High EGR Temperature EGR Temperature : High - moderate severity ture Is High”
(2)
E1093 (1) 411–17 Troubleshooting, “NOx Reduction System

Low EGR Differential Pressure EGR Differential Pressure : Low - least severe (NRS) - Test”
(1)

High EGR Differential Pressure EGR Differential Pressure : High - least severe (NRS) - Test”
(1)

Low EGR Mass Flow Rate EGR Mass Flow Rate : Low - least severe (1) (NRS) - Test”

High EGR Mass Flow Rate EGR Mass Flow Rate : Low - least severe (1) (NRS) - Test”
E1101 (2) 2948–7 Troubleshooting, “Variable Valve Actuator Re-

Intake Valve Actuation System Oil Pressure #1 Engine Intake Valve Actuation System Oil sponse - Test”
Not Responding to Command Pressure : Not Responding Properly

Low Engine Charge Air Cooler #1 Outlet Engine Charge Air Cooler Outlet Temperature Is Low”
Temperature : Low - most severe (3)
E1132 (2) 5588–14 Troubleshooting, “Data Link Configuration Sta-

Inconsistent Configuration Detected Proprietary Network #2 : Special Instruction tus - Test”

Low DPF #1 Intake Pressure DPF #1 Intake Pressure : Low - least severe Low Inlet Pressure”
(1)

Low DPF #1 Intake Pressure DPF #1 Intake Pressure : Low - moderate se- Low Inlet Pressure”
verity (2)

High DPF #1 Intake Pressure DPF #1 Intake Pressure : High - least severe High Inlet Pressure”
(1)
E1170 (1) 3837–17 Troubleshooting, “ARD Combustion Supply Air

Low Aftertreatment #1 Secondary Air Pressure Aftertreatment 1 Secondary Air Pressure : Low Pressure Is Low”
- least severe
E1171 (1) 593–31 Troubleshooting, “Engine Shutdown While
Engine Idle Shutdown Occurred Engine Idle Shutdown has Shutdown Engine Idling”

Engine Idle Shutdown Pending Engine Idle Shutdown Driver Alert Mode Idling”
(continued)
M0070030-01 85
Event Codes
(Table 10, contd)

Engine Idle Shutdown Pending Engine Idle Shutdown Driver Alert Mode Idling”

DPF #1 Conditions Not Met for Active DPF #1 Conditions Not Met for Active
Regeneration Regeneration

DPF #1 Conditions Not Met for Active DPF #1 Conditions Not Met for Active Regen-
Regeneration eration : Low - least severe (1)

DPF #1 Conditions Not Met for Active DPF #1 Conditions Not Met for Active Regen-
Regeneration eration : Low - moderate severity (2)

Aftertreatment Regeneration Cannot Start Due DPF Active Regeneration Inhibited Due to En-
to Low Engine Temperature gine Not Warmed Up : High - least severe (1)

Aftertreatment Regeneration Cannot Start Due DPF Active Regeneration Inhibited Due to En-
to Low Engine Temperature gine Not Warmed Up

Aftertreatment Regeneration Cannot Start Due DPF Active Regeneration Inhibited Due to Sys-
to System Fault tem Fault Active : High - least severe

Aftertreatment Regeneration Cannot Start Due DPF #1 Conditions Not Met for Active Regen-
to Conditions Not Met eration : High - least severe (1)

Initial Assembly Aftertreatment #1 Procedure Aftertreatment #1 Regeneration Status : Other
Required Failure Mode
E1309 (2) 4364–18 Troubleshooting, “NOx Conversion Is Low”

Low Aftertreatment #1 SCR Catalyst Conver- Aftertreatment #1 SCR Catalyst Conversion
sion Efficiency Efficiency : Low - moderate severity (2)
E1363 (1) 1639–17 Troubleshooting, “Cooling Fan Speed - Test”

Low Engine Cooling Fan Speed Fan Speed : Low - least severe (1)

Low Aftertreatment #1 DEF Concentration Catalyst Reagent Concentration : Low - mod-
erate severity (2)

High Aftertreatment #1 DEF Concentration Catalyst Reagent Concentration : High - mod-
erate severity
E1370 (2) 5392–31 Troubleshooting, “DEF Pressure Is Low”

Aftertreatment #1 Diesel Exhaust Fluid Dosing Aftertreatment Diesel Exhaust Fluid Dosing
Unit Loss of Prime Unit Loss of Prime
E1389 (1) 5246–15 Troubleshooting, “SCR Warning System
Aftertreatment #1 SCR Operator Inducement Aftertreatment SCR Operator Inducement Se- Problem”
verity : High - least severe (1)

verity : High - moderate severity (2)

verity : High - most severe (3)
(continued)
86 M0070030-01
Event Codes
(Table 10, contd)

E1398 (2) 3031–18 Troubleshooting, “DEF Temperature Is Low”
Low Aftertreatment #1 SCR Catalyst Reagent Aftertreatment 1 Diesel Exhaust Fluid Tank
Tank #1 Temperature Temperature : Low - moderate severity (2)
E1407 (2) 3217–16 Troubleshooting, “Clean Emissions Module

High Aftertreatment #1 Intake O2 Aftertreatment #1 Intake O2 : High - moderate Has High Oxygen Level”
Concentration severity (2)
E1408 (2) 3227–16 Troubleshooting, “Clean Emissions Module

High Aftertreatment #1 Outlet O2 Aftertreatment #1 Outlet O2 : High - moderate Has High Oxygen Level”
Concentration severity

Invalid Aftertreatment #1 SCR Conversion Aftertreatment #1 SCR Catalyst Conversion
Efficiency Efficiency : Erratic, Intermittent, or Incorrect

Aftertreatment #1 SCR Dosing Pump Temper- Aftertreatment 1 Diesel Exhaust Fluid Dosing
ature Not Responding Unit Heater Temperature : Not Responding
Properly
E1430 (2) 5480–16 Troubleshooting, “DEF Control Module Tem-

High Aftertreatment #1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Control- perature Is High”
Controller Temperature ler Temperature : High - moderate severity (2)
E1431 (2) 3216–7 Troubleshooting, “NOx Sensor - Test”

Invalid Aftertreatment #1 Intake NOx Level #1 Aftertreatment #1 Intake NOx : Not Respond-
ing Properly
E1432 (2) 3226–7 Troubleshooting, “NOx Sensor - Test”

Invalid Aftertreatment #1 Outlet NOx Level #1 Aftertreatment #1 Outlet NOx : Not Respond-
ing Properly

Aftertreatment #1 Diesel Exhaust Fluid Tank Aftertreatment 1 Diesel Exhaust Fluid Tank
Temperature Not Responding Properly Temperature : Not Responding Properly
E1465 (1) 6322–31 Troubleshooting, “Desulfation Is Frequent”

Aftertreatment #1 SCR Desulfation Too Aftertreatment #1 SCR Desulfation Too
Frequent Frequent
E1466 (1) 6588–31 Troubleshooting, “Engine Shutdown

Operator Forced Shutdown with High Exhaust Operator Shutdown With High Exhaust Occurrence”
Temperature Temperature
E2087 (3) 3667–31 Troubleshooting, “Air Shutoff - Test”

Air Intake Shutoff Closed Engine Air Shutoff Status
E2088 (1) 3667–2 Troubleshooting, “Air Shutoff - Test”

Air Intake Shutoff Detection Circuit Detected Engine Air Shutoff Status : Erratic, Intermittent,
but Not Installed or Incorrect
E2112 (1) 109–17 Troubleshooting, “Coolant Pressure Is Low”
Low Engine Coolant Pressure Engine Coolant Pressure : Low - least severe
(1)

Low Engine Coolant Pressure Engine Coolant Pressure - Low - moderate se-
verity (2)

Low Engine Coolant Pressure Engine Coolant Pressure : Low - most severe
(3)
E2143 (1) 111–17 Troubleshooting, “Coolant Level Is Low”

Low Engine Coolant Level Engine Coolant Level - Low - least severe (1)
(continued)
M0070030-01 87
Event Codes
(Table 10, contd)

Low Engine Coolant Level Engine Coolant Level Low - moderate severity
(2)

Low Engine Coolant Level Engine Coolant Level Low - most severe (3)
Parts of the Event Code

Event Code – “E” identifies the code as an event
code. “XXX(X)” represents a numeric identifier for the
event code. The fourth “(X)” assigns one of three
levels to the active event code according to the
severity of the abnormal system condition. Next is a
code description. Refer to the following example:
• E360(1) Low Oil Pressure

The definition for the levels of severity for an event
are defined below:
Level 1 – Level 1 alerts the operator that an engine
system requires attention. The operator should check
that the involved system condition or the operator
should perform maintenance on the involved system
at the earliest possible time.
Level 2 – Level 2 requires a change in the operation
of the engine or the performance of a maintenance
procedure. Failure to correct the problem that caused
this warning may result in damaged the engine
components.
Level 3 – Level 3 requires an immediate safe
shutdown of the engine to avoid damage to the
engine or injury to personnel around the engine. The
problem that caused the event must be corrected
before engine operation can resume.
Active Event Codes Illustration 35 g01365757

An active event code represents a problem with Example of the typical operating range of a sensor
engine operation. Correct the problem as soon as
(1) This area represents the normal operating range of the engine
possible. parameter.
(2) In these areas, the engine is operating in an unsafe operating
Active event codes are listed in ascending numerical range of the monitored parameter. An event code will be
order. The code with the lowest number is listed first. generated for the monitored parameter. The sensor circuit
does not have an electronic problem.
Illustration 35 is an example of the operating range of (3) In these areas, the signal from the sensor is outside of the
a sensor. operating range of the sensor. The sensor circuit has an
electronic problem. A diagnostic code will be generated for the
sensor circuit. Refer to Troubleshooting, “Diagnostic Trouble
Codes” for additional information on diagnostic codes.
88 M0070030-01
Event Codes
Logged Event Codes 4. Perform a visual inspection. Inspect the following

items:
When the Electronic Control Module (ECM)
generates an event code, the ECM logs the code in
• Fuel supply
permanent memory. The ECM has an internal
diagnostic clock. The ECM will record the following
information when an event code is generated: • Oil level
• The hour of the first occurrence of the code • Oil supply
• The hour of the last occurrence of the code • Wiring
• The number of occurrences of the code • Connectors

Logged events are listed in chronological order. The Be sure to check the connectors. This step is
most recent event code is listed first. important for problems that are intermittent. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
This information can be helpful for troubleshooting
intermittent problems. Logged codes can also be If these steps do not resolve the problem, refer to
used to review the performance of the engine. Table 10 or Table 9 for the procedure to troubleshoot
the event code.
Clearing Event Codes
A code is cleared from memory when one of the
following conditions occur:
• The code does not recur for 100 hours.

• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is
cleared.
• The service technician manually clears the code.
Always clear logged event codes after investigating
and correcting the problem which generated the
code.
Troubleshooting
For the basic troubleshooting of the engine, perform
the following steps to diagnose a malfunction:
1. Obtain the following information about the
complaint:
• The event and the time of the event
• Determine the conditions for the event. The

conditions will include the engine rpm and the
load.
• Determine if there are any systems that were

installed by the dealer or by the customer that
could cause the event.
• Determine whether any additional events

occurred.
2. Verify that the complaint is not due to normal

engine operation. Verify that the complaint is not
due to error of the operator.
3. Narrow the probable cause. Consider the operator
information, the conditions of operation, and the
history of the engine.
M0070030-01 89
Symptom Troubleshooting
i06635934
Acceleration Is Poor or
Throttle Response Is Poor
Check the electronic service tool for any associated

codes that are listed in Table 11 . Troubleshoot any
active codes before continuing with this procedure.
Table 11
Associated Diagnostic Trouble Codes
J1939 Code PDL Code

5580–17 E198 (1)
5580–18 E198 (2)
5584–15 E390 (1)
5584–16 E390 (2)
107–15 E583 (1)
107–16 E583 (2)
Probable Causes
• Codes
• Parameters
• Throttle Signal
• Air Inlet and Exhaust System

• Fuel System
• Engine Load
• Valve Lash
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.
90 M0070030-01
Table 12
Troubleshooting Test Steps Values Results
1. Engine Derate or Active Codes Result: A diagnostic code is present.

Engine Derate
A. Certain diagnostic codes and/or event codes may cause poor or Active Codes 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 Result: The parameters are correct.

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

Throttle Signal Proceed to Test Step 4.
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.
4. Restriction in the Air Inlet and Exhaust System Result: There are no restrictions in the air inlet or exhaust
Restrictions 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 5.
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.
(continued)
M0070030-01 91
(Table 12, contd)

5. Check the Fuel System Result: The fuel pressure is OK.
Fuel system
Refer to Systems Operation/Testing and Adjusting, “Fuel System” Proceed to Test Step 6.
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 the Systems Operation,

“General Information”.
F. Check fuel quality. Refer to Systems Operation/Testing and Ad-

justing, “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.
6. Engine Load Engine loads Result: There is not a parasitic load.
A. Check accessories and parasitic loads on the engine. Proceed to Test Step 7.
Result: There is a parasitic load.
Repair: Remove the parasitic load.
7. Valve Lash Valve lash Result: The valve lash is not set correctly.
A. Check the valve lash. The valve lash can affect the perform- Repair: Set the valve lash. Refer to Testing and Adjusting,
ance of the engine. “Engine Valve Lash - Inspect/Adjust” for the correct
procedure.
i06244264 Recommended Actions

Alternator Problem Note: The procedures have been listed in order of
Probable Causes
• Alternator
• Charging Circuit
92 M0070030-01
Table 13
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.
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. 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.
3. 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 4.
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.
4. Operation of the Alternator or Regulator Regulator and Result: The regulator and alternator are operating
alternator properly.
A. Verify that the alternator or the regulator is operating cor-
rectly. Refer to Systems Operation, Testing and Adjusting, Proceed to Test Step 5.
“Charging System - Test” for the proper testing procedures.
Result: The regulator and alternator are not operating
properly.
Repair: Repair the alternator and regulator or replace the

alternator and regulator, as needed. Refer to Disassembly
and Assembly for the correct procedure.
5. Inspection of the Charging Circuit Charging circuit Result: The charging circuit is not working properly.
A. Inspect the battery cables, wiring, and connections in the Repair: Clean all connections and tighten all connections.
charging circuit. Replace any faulty parts.
M0070030-01 93
If the procedure did not correct the issue, contact the

Dealer Solutions Network (DSN).
i06636003
ARD Combustion Supply Air

Pressure Is Low
Table 14 lists the diagnostic codes that relate to the

Aftertreatment Regeneration Devices absolute air
pressure.
Note: Some of the following codes may not be
applicable for certain applications.
Table 14
J1939 Code PDL Code Description Comments

Low Aftertreatment #1 Secondary Air Air pressure to the combustion air valve
3837-17 E1170 (1)
Pressure is low.
System Operation
Note: The technician must perform an “ARD Air
System Service Test” to verify that the problem is
corrected. If the problem has been resolved, perform
a manual DPF regeneration before the unit is
returned to service.
The A5:E2 aftertreatment controller is responsible for
the control of many components on the CEM,
including the combustion air valve. The A5:E2
aftertreatment controller communicates on the CAN
data link to both the A4:E4 engine ECM and the
Diesel Exhaust Fluid Control Unit (DCU). The A5:E2
aftertreatment controller receives inputs from the
sensors on the CEM and on CAN from the other
controllers. The A5:E2 aftertreatment controller uses
these inputs to determine when and what position the
combustion air valve should be opened.
When the A5:E2 aftertreatment controller determines
that the combustion air valve should be opened, the
A5:E2 aftertreatment controller sends a pulse width
modulated (PWM) signal to the valve. This PWM
signal causes the valve to open. A position sensor
located in the combustion air valve assembly then
sends a signal back to the A5:E2 aftertreatment
controller showing the actual position of the valve.
94 M0070030-01
Table 15
J1939 Code PDL Code

102-18 E1045 (2)
3487-5 2489-5
3487-6 2489-6
3487-13 2489-13
3488-3 2490-3
3488-4 2490-4
3609-15 E1156 (1)
3837-3 3493-3
3837-4 3493-4
3837-13 3493-13
Complete the procedure in the order in which the

steps are listed.
Table 16
1. Check for Associated Diagnostic Trouble Codes Code Result: An associated diagnostic trouble code is not
present.
A. Connect the electronic service tool to the diagnostic
connector. Proceed to Test Step 2.
B. Determine if an associated diagnostic code is Result: An associated diagnostic trouble code is

present. present.
Repair: Troubleshoot the associated code.
If the repair does not eliminate the problem, proceed to

Test Step 2.
2. Inspect the Piping Between the Compressor and Piping Result: The piping is damaged or cracked.
the ATAAC
Repair: Replace the piping or repair the piping. Pro-
A. Visually Inspect the piping between the compressor ceed to Test Step 6.
and the ATAAC.
Result: The piping is not damaged or cracked.
B. Check for cracks in the piping.
C. Check for loose hardware or damaged hardware.
M0070030-01 95
(1) Piping between the compressor and the

air valve
Table 17
3. Inspect the Piping Between the Compressor and the Air Damaged or Result: The piping is damaged or cracked.
Valve cracked
piping Repair: Replace the piping or repair the piping. Proceed to
A. Inspect the piping (1) between the compressor and the air Test Step 6.
valve.
B. Check for cracks in the piping.
96 M0070030-01
CEM (typical)
(2) Clamps (3) Piping between the combustion air valve
and the pressure sensor
M0070030-01 97
Table 18
4. Inspect the Piping from the Combustion Air Valve to the Piping Result: The piping is damaged or cracked.
Pressure Sensor
Repair: Replace the piping or repair the piping. Proceed
A. Inspect the piping from the combustion air valve to the pressure to Test Step 6.
sensor (3).
B. Check for air leaks.
D. Check the clamps on the piping. Make sure that the clamps are
tight.
5. Inspect the Turbocharger Turbocharger Result: The turbocharger has failed.
A. Refer to Systems Operation, Testing and Adjusting, Turbocharg- Repair: Replace the turbocharger. Proceed to Test Step
er - Inspect to determine if the turbocharger has failed. 6.
Result: The turbocharger has not failed.
6. Perform the “ ARD Air System Service Test”” Test Result: The test completed successfully.
A. Perform the “ARD Air System Service Test” . Repair: Perform a “Manual DPF Regeneration” and re-
turn the unit to service.
Ensure that the repair eliminated the problem.
Result: The test did not complete successfully.
Repair: Troubleshoot the logged diagnostic code.
Ensure that the repair eliminated the problem.
i06636109
ARD Failed to Ignite
Use this procedure to troubleshoot the following

code:
Note: Refer to Troubleshooting, “Service Tool

Features” for information about service features.
Table 19
J1939 Code PDL Code Code Description Comments
The Aftertreatment Regeneration Device (ARD) has failed to ignite.

Aftertreatment #1
3473-31 E1025 (2) Usually, the “failed to ignite” code is accompanied by another logged
Failed to Ignite
code that indicates the condition that caused the failure to ignite.
98 M0070030-01
Components for the Ignition System

The ignition coil is on the Clean Emissions Module
(CEM) mounting plate. Refer to Illustration 38 .
CEM (typical)
(1) ARD ignition coil (3) Cable for CEM electrical connector to (4) ARD combustion head
(2) Relay for the ARD nozzle heater ECM
System Operation The ARD ignition system has two circuits. The
primary circuit is between the A5:E2 Aftertreatment
Controller and the ARD ignition coil. The secondary
circuit is between the ARD ignition coil and the ARD
spark plug. The current flow through the primary
circuit indicates the condition of the primary circuit
and of the secondary circuit. The ECM monitors the
current flow through the primary circuit. In this way,
the ECM is able to detect problems with the primary
circuit and the secondary circuit.
M0070030-01 99

steps are listed.
Table 20
J1939 Code PDL Code
3837-17 E1170 (1)
3487-7 E1041 (1)
3480-15 E1050 (1)
3480-16 E1050 (2)
3480-17 E1052 (1)
3480-18 E1052 (2)
3609-15 E1156 (1)
4077-15 E1051 (1)
4077-16 E1051 (2)
4077-17 E1053 (1)
4077-18 E1053 (2)
4301-5 3182-5
4301-6 3182-6
A problem with the ignition cir-
cuit is the most likely cause of a
No associated codes
logged E1025 (2) or 3473-31
code with no additional codes.
Table 21
1. Check for Associated Codes Associated Result: An associated code is active or logged.
Codes
A. Establish communication between the electronic service tool Repair: Troubleshoot the associated codes before continu-
and the Electronic Control Module (ECM). ing with this procedure.
Result: An associated code is not active or logged.

B. If any of the associated codes in Table 20 are logged, trouble-
shoot the codes before continuing with this procedure. Proceed to Test Step 2.
(continued)
100 M0070030-01
(Table 21, contd)
2. Inspect the Components Damaged Result: There is a problem with the wiring. A wire end is not
wiring or connected or a wire is damaged.
Carefully following this procedure is a good way to identify wiring connectors
problems. Repair: Repair the wiring. Replace parts, if necessary.
A. Visually inspect the components for the ARD ignition system.
Look for the following problems: Verify that the problem is resolved. If the problem is not re-
solved, proceed to Troubleshooting, “ARD Ignition - Test”.
1. Loose connections or damaged connectors
Result: The wiring is OK.
2. Moisture on the connectors or the wiring
3. Damage that is caused by excessive heat
4. Damage that is caused by chafing
5. Improper routing of wiring
6. Damaged insulation
B. Verify that each end of the ground wire is securely connected to

both ground points.
C. Push the boot on each end of the ignition wire. This action tests
whether the clip inside the boot is connected to the spark plug and
to the ignition coil. There should not be a “click” when you push
the boot onto either part. If you felt a “click” , the clip inside the
boot was not connected.
D. Pull on the end of each harness wire at the 3-pin connector for
the ignition coil. This test verifies that the wire is crimped to the ter-
minal and that the terminal is inserted into the connector.
3. Check the Current Flow to the Heating Element in the ARD 7.0 A and 14 Result: The current flow is between 7.0 A and 14 A for a 12
Combustion Head A for a 12 V V system. Or, the current flow is between 3.5 A and 7 A for a
system 24 V system.
Start the engine. Check the current flow to the heater. Refer to or Result: The current flow is OK.
Systems Operation/Testing and Adjusting, “ARD Nozzle Heater 3.5 A and 7 A
(Current)- Test” for the correct procedure. for a 24 V Proceed to Test Step 4.
system
Result: The current flow is not between 7.0 A and 14 A for a
12 V system. Or, the current flow is not between 3.5 A and 7
A for a 24 V system.
Repair: There may be a problem with the ARD nozzle. Refer

to Troubleshooting, “ARD Nozzle Heater - Test”.
4. Perform the “ ARD Air System Service Test”” Test passed Result The “ARD Air System Service Test” failed.
A. Reset all active codes and clear all logged codes. Use the elec- Repair: There is a problem with the ARD combustion air.
tronic service tool to perform an “ARD Air System Service Test” . Refer to Troubleshooting, “ARD Combustion Air - Test”.
Refer to Troubleshooting, “ARD Combustion Air - Test”.
Result The “ARD Air System Service Test” passed.
M0070030-01 101
T400026 Spark Tester
Table 22
5. Check for Spark Voltage at the Spark Plug Spark Result: There are sparks inside the spark indicator.
A. Disconnect the ignition wire from the spark plug. Turn off the ARD ignition system by disabling the override.
B. Connect the T400026 Spark Tester between ignition wire and
the spark plug. Result: There are no sparks inside the spark indicator.
C. Use the “Aftertreatment #1 Ignition Transformer Primary Over- Turn off the ARD ignition system by disabling the override.
ride” located in the electronic service tool to turn ON the ARD igni- Proceed to Troubleshooting, “ARD Ignition - Test”.
tion system. The override is located in the “Engine #1
Aftertreatment Controller” under “System Troubleshooting Settings”
.
D. Check for spark in the spark indicator.
102 M0070030-01
(5) ARD spark plug
Table 23
6. Clean the Components in the ARD Combustion Head Spark Plug Result: The components are clean. The spark plug is
not damaged.
A. Remove the spark plug(5) from the ARD combustion head.
Install the spark plug.
B. Clean the ground probe inside the ARD combustion head by
running a T400005 Plug Bore Brush through the hole in the ARD Proceed to Test Step 7.
combustion head. Run the brush through the hole several times.
Result: If the spark plug probe is bent, cracked, or has
C. Inspect the spark plug. Look for the following problems: been dropped.
1. Carbon Deposits - Use a nonmetallic cleaning pad to clean the Repair: Replace the spark plug.
spark plug.
2. Bent Probe - If the probe appears to be bent, replace the spark

plug. Otherwise, install the original spark plug. Refer to the Specifi-
cations manual for the correct torque value.
3. Cracked Porcelain - If the porcelain appears to be cracked, re-

place the spark plug. Otherwise, install the original spark plug. Re-
fer to the Specifications manual for the correct torque value.
The spark plug may be damaged if the spark plug is dropped. Do

not install a spark plug that has been dropped.
M0070030-01 103
(6) Flame detection temperature sensor
Table 24
7. Clean the Flame Detection Temperature Sensor Sensor Result: The components are clean. The flame detection
temperature sensor is not damaged. Install the flame de-
A. Remove the flame detection temperature sensor (6). tection sensor.
B. Clean the flame detection temperature sensor. Use a nonmetal- Proceed to Test Step 8.
lic cleaning pad to clean the sensor.
Result: The flame detection temperature is damaged. Re-
place flame detection temperature sensor.
8. Check the ARD for Proper Operation Successful Result: The test is successful.
test
A. Reset all active codes and clear all logged codes. Use the elec- Proceed to Test Step 11.
tronic service tool to perform an “ARD Ignition Test” to verify that
the problem is resolved. Result: The test is not successful.
The ARD Ignition Test cannot be performed if the DPF soot loading Proceed to Test Step 9.
is above 80%. When the DPF soot loading is above 80%, the Man-
ual DPF Regeneration must be performed using the electronic Result: The test is not successful. There are additional
service tool. codes.
Repair: Troubleshoot the additional codes. Refer to Trou-

bleshooting for the correct procedure.
Verify that the problem is resolved.
104 M0070030-01
Components of the ARD combustion head
(7) ARD pilot filter connector (8) ARD main filter connector (If equipped)
Table 25
9. Replace the Pilot Filter Connector at the ARD Combustion Test Result: The test is successful.
Head
A. Flush the ARD fuel system and replace the pilot filter connector
at the ARD combustion head. Refer to Systems Operation/Testing Result: The test is not successful.
and Adjusting, “Fuel System - Flush” for additional information.
B. Reset all active codes and clear all logged codes. Perform the
“ARD Ignition Test” using the electronic service tool and verify that Result: The test is not successful. There are additional
there are no fuel leaks. Refer to System Operation/Testing and Ad- codes.
justing, “ARD Fuel System - Test”.
Repair: Troubleshoot the additional codes. Refer to Trou-
The ARD Ignition Test cannot be performed if the DPF soot loading bleshooting for the correct procedure.
is above 80%. When the DPF soot loading is above 80%, the Man- Verify that the problem is resolved.
ual DPF Regeneration must be performed using the electronic serv-
ice tool.
M0070030-01 105
(9) Fouled slot
(10) Acceptable soot accumulation
106 M0070030-01
Table 26
10. Inspect ARD Swirl Plate Swirl Plate Result: The swirl plate is fouled.
A. Remove ARD head. Refer to Disassembly and Assembly, “Com- Clean the swirl plate. Refer to Testing and Adjusting, “Swirl
bustion Head Group (ARD) - Remove and Install - Clean Emissions Plate (ARD Combustion) - Inspect/Clean”.
Module” for the proper procedure to remove the ARD combustion
head. Repair: Reset all active codes and clear all logged codes.
Perform the “ARD Ignition Test” in the electronic service tool
Soot accumulation is normal. Slot fouling is defined as more than and verify that there are no fuel leaks.
half the inner row slots beingcompletely blocked. Partially blocked
inner row slots are normal and do not affect regeneration perform- The ARD Ignition Test cannot be performed if the DPF soot
ance. Refer to Illustrations 43 and 44 to verify if the swirl plate is loading is above 80%. When the DPF soot loading is above
fouled. 80%, the Manual DPF Regeneration must be performed us-
ing the electronic service tool.
B. Inspect the swirl plate for fouled slots. Refer to Illustrations 43
and 44 to verify if the swirl plate is fouled. Proceed to Test Step 11.
Result: The swirl plate is not fouled.
Repair: Replace the ARD combustion head. Refer to Disas-

sembly and Assembly, “Combustion Head - Remove and
Install”.
Reset all active codes and clear all logged codes. Perform
the “ARD Ignition Test” in the electronic service tool and ver-
ify that there are no fuel leaks.
The ARD Ignition Test cannot be performed if the DPF soot

loading is above 80%. When the DPF soot loading is above
80%, the Manual DPF Regeneration must be performed us-
11. Perform a “ Manual DPF Regeneration”” Successful Result: The “Manual DPF Regeneration” completed suc-
test cessfully. There are no additional codes.
This test must be performed through the electronic service tool. The
electronic service tool enhances the diagnostics during the service Return the unit to service.
test.
Result: The “Manual DPF Regeneration” did not complete
A. Clear all diagnostic codes. successfully. There are additional codes.
B. Start the engine. Allow the engine to idle for 3 minutes. Repair: Troubleshoot the additional codes. Refer to Trou-
bleshooting for the correct procedure.
Do not use the operators switch for stationary regeneration. The Verify that the problem is resolved.
service tests provide enhanced diagnostics that are necessary for
proper troubleshooting and repair.
C. Start a “Manual DPF Regeneration” in the electronic service tool.
i06841098 Note: Refer to Troubleshooting, “Service Tool

ARD Fuel Pressure Is High Note: Some of the following codes may not be
This procedure covers the following diagnostic
trouble codes:
M0070030-01 107
Table 27

High Aftertreatment #1 Fuel Pressure There are Enhanced Troubleshooting In-
3480-15 E1050 (1)
#1 dicators for this code.
High Aftertreatment #1 Fuel Pressure There are not Enhanced Troubleshooting

3480-16 E1050 (2)
#1 Indicators for this code.
High Aftertreatment #1 Fuel Pressure There are Enhanced Troubleshooting In-
4077-15 E1051 (1)
#2 dicators for this code.
High Aftertreatment #1 Fuel Pressure There are not Enhanced Troubleshooting
4077-16 E1051 (2)
#2 Indicators for this code.
Table 28
Required Parts for Use with a 11/16 Fitting
T400008 Pressure Gauge
T402294 Tee
T408416 O-Ring Seal (Tee)
T400009 Quick Connect Coupler
CH11410 Fitting
CH10046 O-Ring Seal
T400007 Swivel Tee

CH11880 O-Ring Seal (Tee)
CH11410 Fitting
CH10046 O-Ring Seal

steps are listed.
108 M0070030-01
Table 29
1. Check the current flow to the heating element in the ARD Current Result: The current flow is between 7.0 A and 14 A for a 12
combustion head Check V system. Or, the current flow is between 3.5 A and 7 A for
a 24 V system.
A. Start the engine. Use a clamp-on ammeter to check the current
flow to the heater. The current flow is OK. Proceed to Test Step 2.
Result: The current flow is not between 7.0 A and 14 A for

a 12 V system. Or, the current flow is not between 3.5 A
and 7 A for a 24 V system.
Repair : There may be a problem with the ARD nozzle. Re-

fer to Troubleshooting, “ARD Nozzle Heater - Test”.
STOP.
2. Perform an ARD Ignition Test and Record the Enhanced ETI Code Result : There is not an ETI for the diagnostic code.
Troubleshooting Indicator (ETI)
A. Establish communication between the electronic service tool and
the Electronic Control Module (ECM). Refer to Troubleshooting, Result : The ETI code was recorded.
“Electronic Service Tools”, if necessary.
B. Perform an ARD Ignition Test using the electronic service tool.
Refer to System Operation and Testing and Adjusting, “ARD Fuel
System - Test”.
C. The ETI code is located in the “Active Events” or “Logged Events”

screen in the electronic service tool. Record the Enhanced Trouble-
shooting Indicator (ETI) code.
ETI codes are not available for (2) codes.
Note: The ARD Ignition Test cannot be performed if

the DPF soot loading is above 80%. When the DPF
soot loading is above 80%, the Manual DPF
Regeneration must be performed using the electronic
service tool.
M0070030-01 109
Table 30
3. Check the Fuel Diverter Valve Pressure Result: The pressure reading was greater than 758 kPa
Checkout (110 psi).
A. Turn the engine OFF.
Repair : Replace the diverter valve. Perform an “ARD Igni-
B. Disconnect the ARD fuel line from the pump. tion Test” using the electronic service tool. Refer to System
Operation and Testing and Adjusting, “ARD Fuel System -
C. Install the required parts listed in Table 28 at the outlet port of the Test”.
pump. The ARD Ignition Test cannot be performed if the DPF soot
D. Turn the keyswitch to the ON position. 80%, the Manual DPF Regeneration must be performed us-
E. Establish communications between the electronic service tool
and the Engine ECM. Result: The pressure reading was less than 758 kPa
(110 psi).
F. Clear the active event code or the override will not activate.
G. Select “Fuel Priming Command Override” in the electronic serv-
ice tool to activate the pump.
H. Override the pump and record the pressure from the pressure
gauge.
I. Deactivate the override.
J. Turn the keyswitch to the OFF position.
110 M0070030-01
(1) Diverter Valve (3) Regulator

(2) Pump (4) Base Assembly
M0070030-01 111
(5) Outlet port of the pump
112 M0070030-01
Table 31
4. Check the Pump Pump Result: The pressure measured greater than
1900 ± 120 kPa (275 ± 17.4 psi).
A. Start the engine.
Result : Replace the pressure regulator. Perform an “ARD
B. Clear the active event code or the override will not activate. Ignition Test” using the electronic service tool. Refer to Sys-
tem Operation and Testing and Adjusting, “ARD Fuel Sys-
C. Connect to the Engine #1 Aftertreatment ECM using the elec- tem - Test”.
tronic service tool.
D. Select the “Aftertreatment Fuel Pump Relay Override” to activate loading is above 80%. When the DPF soot loading is above
the pump. 80%, the Manual DPF Regeneration must be performed us-
E. Override the pump and record the pressure from the pressure
gauge. Result: The pump is within specifications.
F. Deactivate the override. If you are troubleshooting an E1050 (1) or E1051 (1) code
with an ETI of 5 or 6, Proceed to Test Step 5.
G. Turn the keyswitch to the OFF position.
Result: The pump is within specifications.
H. The pressure must be within specifications. The pump pressure
must be 1900 ± 120 kPa (275.5 ± 17.4 psi). If you are troubleshooting an E1050 (1) code with an ETI of
1 or an E1050 (2), Proceed to Test Step 6.
Result: The pump is within specifications.
If you are troubleshooting an E1051 (1) code with an ETI of

1 or an E1051 (2), Proceed to Test Step 7.
ETI codes are not available for (2) codes.
ARD head (typical)
(6) Pilot fitting that contains the filter (7) Main fitting that contains the filter (If
equipped)
M0070030-01 113
Table 32
5. Replace the Fittings that Contain the Filter in the ARD Head Replace fil- Result: The “ARD Ignition Test” was successful and no co-
ter fittings des were logged.
A. Replace the fittings that contain the filters in the ARD head. Return the unit to service.
B. Reset all active codes and clear all logged codes by cycling the STOP
keyswitch to the OFF position.
Result: The “ARD Ignition Test” was not successful and co-
C. Perform the “ARD Ignition Test” using the electronic service tool. des were logged.
System - Test”. If troubleshooting an E1050 (1) code with an ETI of 5 or 6
or an E1050 (2) code, Proceed to Test Step 6.
Result: The “ARD Ignition Test” was not successful and co-
des were logged.
If troubleshooting an E1051 (1) code with an ETI of 5 or 6

or an E1051 (2) code, Proceed to Test Step 7.

service tool.
114 M0070030-01
CEM (typical)
(8) Main solenoid valve (9) Pilot solenoid valve
M0070030-01 115
Table 33
6. Replace the Pilot Solenoid Valve Pilot Sole- Result: The “ARD Ignition Test” was successful and no co-
noid Valve des were logged.
A. Replace the pilot solenoid valve. Return the unit to service.
Result: The “ARD Ignition Test” was not successful.
C. Perform the “ARD Ignition Test” using the electronic service tool.
Refer to System Operation and Testing and Adjusting, “ARD Fuel Proceed to Test Step 8
System - Test”.
7. Replace the Main Solenoid Valve Main Sole- Result: The “ARD Ignition Test” was successful and no co-
noid Valve des were logged.
A. Replace the main solenoid valve. Return the unit to service.
Result: The “ARD Ignition Test” was not successful.
Refer to System Operation and Testing and Adjusting, “ARD Fuel Proceed to Test Step 8
System - Test”.
8. Replace the ARD Head ARD Head Result: The “ARD Ignition Test” was successful and no co-
des were logged.
A. Replace the ARD head. Return the unit to service.
System - Test”.

service tool.
i06651024
ARD Fuel Pressure Is Low

trouble codes:

116 M0070030-01
Table 34

Low Aftertreatment #1 Fuel Pressure #1 - There are Enhanced Troubleshooting In-
3480-17 E1052 (1)
Least Severe dicators for this code.
Low Aftertreatment #1 Fuel Pressure #1 - There are not Enhanced Troubleshooting
3480-18 E1052 (2)
Moderate Severity Indicators for this code.
Low Aftertreatment #1 Fuel Pressure #2 - There are Enhanced Troubleshooting In-

4077-17 E1053 (1)
Least Severe dicators for this code.
Low Aftertreatment #1 Fuel Pressure #2 - There are not Enhanced Troubleshooting
4077-18 E1053 (2)
Moderate Severity Indicators for this code.
Table 35
T402294 Tee
T408416 O-Ring Seal (Tee)
CH11410 Fitting
CH10046 O-Ring Seal
T400007 Swivel Tee

CH11880 O-Ring Seal (Tee)
CH11410 Fitting
CH10046 O-Ring Seal
Table 36
J1939 Code PDL Code

5580-18 E198
3427-5 5423-5
3427-6 5423-6

steps are listed.
M0070030-01 117
Table 37
1. Check for Associated Diagnostic Trouble Codes
Associated Di- Result: A 5580-18 or E198 code is not active. Proceed to
A. Establish communication between the electronic service tool agnostic Trou- Test Step 2.
and the Electronic Control Module (ECM) . Refer to Troubleshoot- ble Codes
ing, “Electronic Service Tools”, if necessary. Result: A 5580-18 or E198 code is active.
Refer to Troubleshooting, “Fuel Pressure Is Low” for the
B. Check for associated diagnostic trouble codes. proper troubleshooting procedure. STOP.
Result: A 3427-5, 3427-6, 5423-5, or 5423-6 code is

active.
Refer to Troubleshooting, Solenoid Valve - Test for the cor-
rect troubleshooting procedure.
2. Record the Enhanced Troubleshooting Indicator (ETI)

Code ETI Code Result: Record the ETI code if present.
A. Establish communication between the electronic service tool
and the Electronic Control Module (ECM) . Refer to Troubleshoot-
ing, “Electronic Service Tools”, if necessary.
B. The ETI code is located in the “Active Events” or “Logged

Events” screen in the electronic service tool. Record the En-
hanced Troubleshooting Indicator (ETI) code.
ETI codes are not available for (2) or -18 codes.
118 M0070030-01
M0070030-01 119
Table 38
3. Check for External Leaks
External Leaks Result: A leak or pinched line was not found.
A. Check for external leaks. Inspect the fuel lines from the pump Proceed to Test Step 4.
to the fuel manifold. Check for pinched lines or leaking lines.
Result: A leak or pinched line was found.
Repair: Repair all damaged lines or leaking lines. Perform

the “ARD Ignition Test” by using the electronic service tool.
Refer to System Operation and Testing and Adjusting,
“ARD Fuel System - Test”. If the “ARD Ignition Test” was
successful, return the unit to service.
If the ARD ignition test was not successful, Proceed to Test

Step 4.
120 M0070030-01
Table 39
4. Check for Electrical Power at the Fuel Priming Pump

3 VDC Result: The voltage at the ARD fuel pump is within 3 VDC
A. Turn the keyswitch to the ON position. Do not start the engine. of the battery voltage.
B. Establish communication between the electronic service tool
and the engine ECM. Select “Fuel Priming Command Override” Result: The voltage at the ARD fuel pump is not within 3
or use the manual priming switch (if equipped) to activate the VDC of the battery voltage.
ARD fuel pump. Refer to Troubleshooting, “Service Tool Fea- Repair: There is a problem with the power supply circuit to
tures” for information about service features. the ARD fuel pump. Check the circuit protection device,
the relay, and the ground for the ARD fuel pump circuit.
C. Check for voltage between pin 1 and pin 2 on the connector to Refer to the machine-specific wiring diagram to trouble-
the fuel priming pump. Check the voltage when the pump is in shoot the circuit. Perform an “ARD Ignition Test” to verify
override. Voltage is not present unless the pump is priming. the repair.
D. Deactivate the override.
E. Turn the keyswitch to the OFF position.
F. Check the voltage at the battery.
M0070030-01 121
ARD electric pump
(1) Pump (2) Base Assembly
122 M0070030-01
ARD electric pump
(3) Output port of the pump
M0070030-01 123
Assembled required parts
Table 40
5. Check the Pump 1900 ± 120 Result: The pump is not within specifications.
kPa
A. Turn the engine “OFF” . (275.5 ± 17.4 Repair: Refer to Troubleshooting, “ARD Fuel Supply - Test”
psi) for troubleshooting information.
B. Disconnect the ARD fuel line from the pump. STOP
C. Install the required parts listed in Table 35 at the outlet port of Result: The pump is within specifications.
the pump.
If you are troubleshooting a E1052 (1) or 3480-17 diagnostic
D. Start the engine. code or a E1053 (1) or 4077-17 diagnostic code with an ETI
of 2 or 3, proceed to Test Step 6.
E. Select the “Aftertreatment Fuel Pump Relay Override” in the
“Engine #1 Aftertreatment Controller” using the electronic service Result: The pump is within specifications.
tool to activate the pump.
If you are troubleshooting an E1052 (2) or 3480-18 diagnos-
F. Override the pump and record the pressure from the pressure tic code, proceed to Test Step 7.
gauge.
If you are troubleshooting a E1053 (2) or 4077-18 diagnostic
G. Deactivate the override. code, proceed to Test Step 8.
H. Turn the keyswitch to the OFF position.
I. The pressure must be within specifications. The pump pressure

must be 1900 ± 120 kPa (275.5 ± 17.4 psi).
124 M0070030-01
CEM (typical)
(4) Fuel filter fitting
Table 41
6. Replace the Filter for the ARD Fuel Manifold Filter Result: The “ARD Ignition Test” was successful and no codes
were logged. Return the unit to service.
A. Replace the filter for the ARD fuel manifold.
STOP
B. Reset all active codes and clear all logged codes by using
the electronic service tool. Result: The “ARD Ignition Test” was not successful.
If you are troubleshooting an E1052 (1) or 3480-17 code with
C. Perform the “ARD Ignition Test” by using the electronic serv- an ETI of 2, Proceed to Test Step 7.
ice tool. Refer to System Operation and Testing and Adjusting,
“ARD Fuel System - Test”. Result: The “ARD Ignition Test” was not successful.
If you are troubleshooting an E1053 (1) or 4077-17 code with
The ARD Ignition Test cannot be performed if the DPF soot an ETI of 2, Proceed to Test Step 8.
80%, the Manual DPF Regeneration must be performed using
the electronic service tool.
M0070030-01 125
CEM (typical)
(5) Main solenoid valve (6) Pilot solenoid valve
126 M0070030-01
Table 42
7. Replace the Pilot Solenoid Valve Result: The “ARD Ignition Test” was successful and no co-
Pilot Valve des were logged. Return the unit to service.
A. Replace the pilot solenoid valve.
STOP
B. Reset all active codes and clear all logged codes by using the
electronic service tool.
C. Perform the “ARD Ignition Test” . Refer to Troubleshooting,

“ARD Ignition - Test”.
The ARD Ignition Test cannot be performed if the DPF soot load-
ing is above 80%. When the DPF soot loading is above 80%, the
Manual DPF Regeneration must be performed using the elec-
8. Replace the Main Solenoid Valve Result: The “ARD Ignition Test” was successful and no co-
Main Valve des were logged. Return the unit to service.
A. Replace the main solenoid valve.
STOP
B. Reset all active codes and clear all logged codes by using the
C. Perform the “ARD Ignition Test” . Refer to Troubleshooting,

“ARD Ignition - Test”.
i06651098 If conditions allow that active regeneration may

begin, the ECM will illuminate the appropriate
ARD Is Disabled indicators and begin the active regeneration. If
conditions will not allow active regeneration to begin,
the ECM will illuminate the Action Lamp and
annunciate one of the following Diagnostic Trouble
Use this procedure to troubleshoot a failed Codes (DTCs). The code will appear on the
aftertreatment regeneration or use this procedure if Messenger Display. The code will also be displayed
one of the following event codes are active. Refer to on the electronic service tool.
Troubleshooting, “Event Codes” for information about
event codes. For information on the engine Note: One forced regeneration per key cycle is
monitoring system, refer to Troubleshooting, “Engine permitted if a failure to ignite, insufficient temperature
Monitoring System”. to complete regeneration, or loss of combustion
diagnostic trouble code is active. This regeneration
Active regenerations usually occur during normal determines if the regeneration can run and clear the
engine operation. However, engine operation or event.
operator desire may cause the operator to activate
the force regeneration switch. This switch signals the
Engine Electronic Control Module (ECM) that a
forced regeneration is desired. The engine ECM will
determine the status of the engine and the products
operating condition and determine if active
regeneration can begin. The elapsed time is
approximately 5 seconds for the engine ECM to
determine if the conditions are acceptable for active
regeneration to begin.
M0070030-01 127
Table 43
Code Description
Initial assembly of the aftertreatment system is com-

Initial Assembly Aftertreatment #1 Procedure
3483-11 E1305 (1) plete or the Engine ECM or the A5:E2 Aftertreatment
Required
Controller was replaced.
The regeneration system is disabled by the electronic

3530-31 E1040 (2) ARD Manually Disabled
service tool.
The coolant temperature is below 40° C (104° F) and
the Diesel Particulate Filter inlet temperature is below
Aftertreatment Regeneration Cannot Start Due to 50° C (122° F).
3716-15 E1300 (1)
Low Engine Temperature If the ambient temperature is 0° C (32° F) or below,
the coolant temperature must be 60° C (140° F) for
active regeneration to begin.
DPF Active Regeneration Inhibited Due to Inhibit The regeneration system is disabled due to the ARD
3703-31 E993 (2)
Switch Disable Switch in the operator interface.
Aftertreatment Regeneration Cannot Start Due To There is an active fault related to the ARD combustion
3712-15 E1301 (1)
System Fault air system, ARD fuel system, or ARD ignition system.
The coolant temperature is below 40° C (104° F) and

the Diesel Particulate Filter inlet temperature is below
Aftertreatment Regeneration Cannot Start Due To 50° C (122° F).
3716-31 E1300 (2)
Low Engine Temperature If the ambient temperature is 0° C (32° F) or below,
the coolant temperature must be 60° C (140° F) for
active regeneration to begin.
Aftertreatment Regeneration Cannot Start Due To One or more conditions are not allowing an Aftertreat-
3750-15 E1302 (1)
Conditions Not Met ment Regeneration to start, Refer to Test Step 7.
The operator did not allow regeneration to occur and

32 hours has elapsed since the last successful regen-
3750-17 E1239 (2) DPF #1 Conditions Not Met for Active Regeneration eration. The operator must respond when the DPF
lamp and action lamp is illuminated. This event will
trigger a 50% derate.
The operator did not allow regeneration to occur and

38.4 hours has elapsed since the last successful re-
generation. The operator must respond when the DPF
3750-18 E1239 (3) DPF #1 Conditions Not Met for Active Regeneration
lamp, or action lamp is illuminated, and an audible
alarm sounds in the cab. This event will trigger a
100% derate.
The operator did not allow enough time for regenera-

tion to occur. The operator must respond when the
3750-31 E1239 (1) DPF #1 Conditions Not Met for Active Regeneration
DPF lamp is illuminated. The operator must allow the
engine to idle until the regeneration is complete.

steps are listed.
128 M0070030-01
Table 44
1. Check for Diagnostic Codes that are Active Diagnostic Code Result: A E1239 (1), E1239 (2), E1239 (3), 3750-31, 3750-
17, or 3750-18 diagnostic code is present, proceed to Test
A. Establish communication between the electronic service Step 2.
tool and the Electronic Control Module (ECM). Refer to Trou-
bleshooting, “Electronic Service Tools”, if necessary. Result: A E993 (3) or 3703-31 diagnostic code is present,
proceed to Test Step 3.
B. Check and record any event codes that are active or
logged. Result: A E1040 (2) or 3530-31 diagnostic code is present,
Result: An E1300 (1), E1300 (2), 3716-15 or 3716-31 diag-

nostic code is present, proceed to Test Step 5.
Result: A E1301 (1) or 3712-15 diagnostic code is present,



2. A E1239 (1), E1239 (2), E1239 (3), 3750-31, 3750-17, or Forced Result: The “Forced Regeneration” was successful.
3750-18 Diagnostic Code is Present. Regeneration
Return the unit to service.
A. The operator did not allow regeneration to occur or auto-
matic regeneration did not occur within the required time limit. Result: The “Forced Regeneration” was not successful.
The operator must respond when the DPF lamp is illuminated.
Repair: Troubleshoot the active diagnostic codes.
B. Perform a “Forced Regeneration” by pressing the “Regen-
eration Force Switch” button.
3. A E993 (3) or 3703-31 Diagnostic Code is Present. Disabled Result: Perform a manual regeneration. Refer to the Opera-
Regeneration tion and Maintenance Manual, “Diesel Particulate Filter Re-
A. The operator has disabled the regeneration system and regeneration” for the proper operation of the regeneration
generation is necessary. system.
4. A E1040 (2) or 3530-31 Diagnostic Code is Present. Regeneration Result: Establish communication between the electronic
Disabled by the service tool and the engine ECM. Set the value of the “After-
A. The regeneration system is disabled by the electronic serv- electronic service treatment Regeneration Device” from “Disabled” to “En-
ice tool. tool. abled” .
5. Aftertreatment Regeneration Cannot Start Due To Low Low Engine Result: Raise the coolant temperature above 40° C
Engine Temperature Temperature (104° F) and the Diesel Particulate Filter inlet temperature
above 50° C (122° F). If the ambient temperature is −15° C
A. The engine temperature is too low for an aftertreatment (5° F) or below, the coolant temperature must be above
regeneration. 60° C (140° F) for active regeneration to begin.
(continued)
M0070030-01 129
(Table 44, contd)

6. Aftertreatment Regeneration Cannot Start Due to Sys- System Fault Result: Troubleshoot all active faults related to the ARD
tem Fault combustion air system, ARD fuel system, or ARD ignition
system. Clear any active codes after correcting the faults.
A. Establish communication between the electronic service Activate regeneration.
tool and the engine Electronic Control Module (ECM).
B. Check for active faults related to the ARD combustion air
system, ARD fuel system, or ARD ignition system.
7. Aftertreatment Regeneration Cannot Start Due to Con- Unacceptable Result: Correct any of the listed conditions. Activate
ditions Not Met Conditions regeneration.
If an excessive DPF intake temperature is present, reduce
A. Check for the following conditions: engine speed and/or load and perform a low speed
regeneration
1. Soot load is too high (116% plus 10 minutes after getting a
level 3 high soot warning) Return the unit to service.
2. The “Time to Regenerate” is greater than 8 hours
3. Incorrect work mode conditions (parking brake is not set,

transmission is not in neutral)
4. Engine speed and load conditions inhibit the forced regen-

eration request
5. Excessive DPF intake temperature. This condition can be

caused by high engine speed and/or high load
6. Regenerations are not disabled
7. For Industrial applications, Refer to the OEM wiring sche-

matic to ensure that the CEM is wired correctly for automatic
regenerations if applicable
8. An active derate, pressure based or temperature-based

event codes
9. An ARD Nozzle Heater cycle was active when the Force

Regeneration switch was pressed.
8. Initial Assembly Aftertreatment #1 Regeneration Total Operating Result: The “Total Operating Hours” is less than 100 hours.
Required Hours
Repair: Complete an “Aftertreatment System Functional
A. Establish communication between the electronic service Test” using the electronic service tool to clear the E1305 or
tool and the engine Electronic Control Module (ECM). 3483-11 code.
B. Under the “Information” menu, select “Current Totals” . Re- Result: The “Total Operating Hours” is greater than 100
cord the “Total Operating Hours” . hours.
Repair: Complete an “Ash Service Regeneration” using the

electronic service tool to clear the E1305 or 3483-11 code.
130 M0070030-01
i06653269
ARD Loss of Combustion
Table 45 lists the diagnostic code that relates to the

combustion air system.


Table 45

The Aftertreatment Regeneration Device (ARD) has stopped generat-
ing heat at least four times during active high-speed regeneration.
Associated codes may indicate the system that caused the loss of
Aftertreatment #1 Loss of combustion to occur.
3474-14 E1026 (1)
Combustion The code must be cleared with the “Reset All” button on the active di-
agnostics screen in the electronic service tool. If active regeneration is
initiated with the operator forced regeneration switch, the Engine Con-
trol Module (ECM) clears this code automatically.
The ARD has stopped generating heat at least four times during active
regeneration.
Associated codes may indicate the system that caused the loss of
Aftertreatment #1 Loss of combustion to occur.
3474-31 E1026 (2)
Combustion The code must be cleared with the “Reset All” button on the active di-
agnostics screen in the electronic service tool. If active regeneration is
initiated with the operator forced regeneration switch, the ECM clears
this code automatically.
System Operation
The combustion air system routes pressurized air
from the outlet of the turbocharger compressor to the
ARD. The combustion air is mixed with fuel inside the
ARD. The air/fuel mixture is ignited and the air/fuel
mixture is burned to provide heat for the diesel
particulate filter.
M0070030-01 131
Typical combustion air system
(1) Outlet for the combustion air to ARD
combustion head
132 M0070030-01
Overview for the ARD combustion head
(2) Flame detection temperature sensor (4) ARD pilot filter connector (7) ARD spark plug
(3) Electrical connection for the ARD nozzle (5) ARD main filter connector (8) Inlet for the combustion air
heater (6) ARD combustion head
When the A5:E2 aftertreatment controller determines

that the combustion air valve should be opened, the
controller sends a pulse width modulated (PWM)
signal to the valve. This PWM signal causes the
valve to open. A position sensor located in the
combustion air valve assembly then sends a signal
back to the A5:E2 aftertreatment controller showing
the actual position of the valve.
Table 46
J1939 Code PDL Code
102-18 E1045
3480-15 or 3480-16 E1050
3480-17 or 3480-18 E1052
3487-7 E1041 (1)
4077-15 or 4077–16 E1051

4077-17 or 4077-18 E1053

steps are listed.
M0070030-01 133
Table 47
1. Check for Associated Diagnostic Trouble Codes Diagnostic Code Result: An associated diagnostic trouble code is not
present.
A. Establish communication between the electronic service
tool and the Electronic Control Module (ECM). Refer to Trou- Proceed to Test Step 2.
bleshooting, “Electronic Service Tools”, if necessary.
Result: An associated diagnostic trouble code is
B. If troubleshooting a E1026 or a 3474 code, access the present.
“Aftertreatment Regeneration History” in the electronic serv-
ice tool. Click the information tab, then click History, and then Repair: Refer to Troubleshooting, “Diagnostic Trouble
click Aftertreatment Regeneration History. If there were three Codes” or Troubleshooting, “Event Codes”to trouble-
successful regenerations since the code was logged, do not shoot the associated diagnostic code.
troubleshoot this code. Clear the code and return the unit to
service.
Table 46 lists the diagnostic trouble codes that are associated

with an E1026 code. Determine if any of the codes in Table 46
are present.
2. Check the Current Flow Through the Heater Between 7.0 A and 14 Result: The current flow is OK.
A for a 12 V system.
A. Verify that the engine is off. Use a clamp-on ammeter to Or, between 3.5 A Proceed to Test Step 3.
check the current flow through the heater. and 7 A for a 24 V
system Result: The current flow is not between 7.0 A and 14 A
for a 12 V system. Or, the current flow is not between
3.5 A and 7 A for a 24 V system.
Repair: There may be a problem with the ARD nozzle.

Refer to Troubleshooting, “ARD Nozzle Heater - Test”.
3. Perform the “ ARD Air System Service Test”” ARD Air System Serv- Result: The “ARD Air System Service Test” failed.
ice Test
A. Reset all active codes and clear all logged codes. Use the Repair: There is a problem with the ARD combustion air
electronic service tool to perform an “ARD Air System Service system. Refer to Troubleshooting, “ARD Combustion Air
Test” to verify that the problem is resolved. - Test”.
Result: The “ARD Air System Service Test” passed.
134 M0070030-01
Table 48
4. Clean the Flame Detection Temperature Sensor Flame Detection Result: The components are clean. The flame detection
Temperature temperature sensor is not damaged.
A. Remove flame detection temperature sensor (2). Sensor
Repair: Install the flame detection sensor.
B. Clean the flame detection temperature sensor. Use a non-
metallic cleaning pad to clean the sensor. Proceed to Test Step 5.
Result: The flame detection temperature is damaged.
Repair: Replace flame detection temperature sensor.
5. Check the ARD for Proper Operation ARD Ignition Test Result: The test is successful.
A. Reset all active codes and clear all logged codes. Use the Proceed to Test Step 8.
electronic service tool to perform an “ARD Ignition Test” to veri-
fy that the problem is resolved. Result: The test is not successful.
The ARD Ignition Test cannot be performed if the DPF soot Proceed to Test Step 6.
ARD head (typical)
(9) Pilot fitting that contains the filter (10) Main fitting that contains the filter (If
equipped)
M0070030-01 135
Table 49
6. Replace the Fittings that Contain the Filter in the ARD Filter Fittings Result: The “ARD Ignition Test” was successful and no co-
Head des were logged.
A. Replace the fittings that contain the filters in the ARD head. Proceed to Test Step 8.
B. Reset all active codes and clear all logged codes by using Result: The “ARD Ignition Test” was not successful.
C. Perform the “ARD Ignition Test” using the electronic service
tool. Refer to System Operation and Testing and Adjusting,
“ARD Fuel System - Test”.

(19) Fouled slot
136 M0070030-01
(20) Acceptable soot accumulation
M0070030-01 137
Table 50
7. Inspect ARD Swirl Plate Swirl Plate Result: The swirl plate is fouled.
A. Remove ARD head. Refer to Disassembly and Assembly, Repair: Clean the swirl plate. Refer to Testing and Adjust-
“Combustion Head Group (ARD) - Remove and Install - Clean ing, “Swirl Plate (ARD Combustion) - Inspect/Clean”.
Emissions Module” for the proper procedure to remove the
ARD combustion head. Reset all active codes and clear all logged codes. Perform
the “ARD Ignition Test” in the electronic service tool and
Soot accumulation is normal. Slot fouling is defined as more verify that there are no fuel leaks.
than 1/2 the inner row slots being completelyblocked. Partially
blocked inner row slots are normal and do not affect regenera- The ARD Ignition Test cannot be performed if the DPF soot
tion performance. Refer to Illustrations 62 and 63 to verify if the loading is above 80%. When the DPF soot loading is above
swirl plate is fouled. 80%, the Manual DPF Regeneration must be performed us-
B. Inspect the swirl plate for fouled slots. Refer to Illustrations
62 and 63 to verify if the swirl plate is fouled. Proceed to Test Step 8.
Result: The swirl plate is not fouled.
Repair: Replace the ARD combustion head. Refer to Dis-

assembly and Assembly, “Combustion Head - Remove and
Install”.
Reset all active codes and clear all logged codes. Perform
the “ARD Ignition Test” in the electronic service tool and
verify that there are no fuel leaks.

80%, the Manual DPF Regeneration must be performed us-
8. Perform a “ Manual DPF Regeneration”” Manual DPF Result: The “Manual DPF Regeneration” completed suc-
Regeneration cessfully. There are no additional codes.
This test must be performed through the electronic service
tool. The electronic service tool enhances the diagnostics Return the unit to service.
during the service test.
A. Clear all diagnostic codes using the electronic service tool. successfully. There are additional codes.
B. Start the engine. Allow the engine to idle for 3 minutes. Repair: Troubleshoot the additional codes before returning
the unit to service. Refer to Troubleshooting for the correct
Do not use the operators switch for a stationary regeneration. procedure.
The service tests provide enhanced diagnostics that are neces-
sary for proper troubleshooting and repair. Verify that the problem is resolved.
C. Start a “Manual DPF Regeneration” in the electronic service

tool.

ARD Temperature Is Low
Table 51 lists the diagnostic code that relates to low

Aftertreatment Regeneration Device (ARD)
temperature.
138 M0070030-01
Table 51
Code Description
(code descriptions may vary) Comments
J1939 Code PDL Code
Active regeneration failed due to an inability of the
Aftertreatment Insufficient Temperature to Diesel Particulate Filter (DPF) to reach a high
3711-31 E593 (2)
Complete Regeneration enough temperature. The code is logged. Engine
power is derated.
Table 52
J1939 Code PDL Code

102-18 E1045 (2)
3480-15 E1050 (1)
3480-16 E1050 (2)
3480-17 E1052 (1)
3480-18 E1052 (2)
4077-15 E1051 (1)
4077-16 E1051 (2)
4077-17 E1053 (1)
4077-18 E1053 (2)
M0070030-01 139
ARD combustion head (typical)
(1) Flame detection temperature sensor (3) ARD pilot filter connector (5) ARD combustion head
(2) Port for the heated nozzle (4) ARD main filter connector (6) Inlet for the combustion air

steps are listed.
140 M0070030-01
Table 53
1. Check for Associated Diagnostic Trouble Codes Diagnostic Code Result: An associated diagnostic trouble code is not
present.
A. Establish communication between the electronic service
tool and the Electronic Control Module (ECM). Refer to Trou- Proceed to Test Step 2.
Result: An associated diagnostic trouble code is present.
B. Table 52 lists the diagnostic trouble codes that are associ-
ated with the E593 (2) or 3711-31 code. Determine if any of the Repair: Troubleshoot the associated diagnostic code.
codes in Table 52 are present.
2. Check the Current Flow Through the Heater Between 7.0 A Result: The current flow is OK.
and 14 A for a 12
A. Verify that the engine is off. Use a clamp-on ammeter to V system. Or, be- Proceed to Test Step 3.
check the current flow through the heater. tween 3.5 A and
7 A for a 24 V Result: The current flow is not between 7.0 A and 14 A for
system a 12 V system. Or, the current flow is not between 3.5 A
and 7 A for a 24 V system.
Repair: There may be a problem with the ARD nozzle. Re-

fer to Troubleshooting, “ARD Nozzle Heater - Test”.
3. Perform the “ ARD Air System Service Test”” ARD Air System Result: The “ARD Air System Service Test” failed.
Service Test
A. Reset all active codes and clear all logged codes. Use the Repair: There is a problem with the ARD combustion air
electronic service tool to perform an “ARD Air System Service system. Refer to Troubleshooting, “ARD Combustion Air -
Test” to verify that the problem is resolved. Test”.
Result: The “ARD Air System Service Test” passed.
This test must be performed through the electronic serv-
ice tool. The electronic service tool enhances the diagnos- Return the unit to service.
tics during the service test.
A. Clear all diagnostic codes. successfully.
B. Start the engine. Allow the engine to idle for 3 minutes. Repair: Check the list of active diagnostic codes. Trouble-
shoot the code that applies to the failed regeneration. Refer
Do not use the operators switch for a stationary regeneration. to Table 52 for associated codes.
The service tests provide enhanced diagnostics that are nec-
essary for proper troubleshooting and repair. Result: The “Manual DPF Regeneration” did not complete
successfully and there are no associated codes.
C. Start a “Manual DPF Regeneration” in the electronic service
tool. Proceed to Test Step 5.
M0070030-01 141
Table 54
5. Replace the Fittings that Contain the Filter in the ARD Filter Fittings Result: The “ARD Ignition Test” was successful and no co-
Head des were logged.
A. Replace the fittings that contain the filters in the ARD head. Proceed to Test Step 6.
B. Reset all active codes and clear all logged codes by using Result: The “ARD Ignition Test” was not successful.
C. Perform the “ARD Ignition Test” using the electronic service
tool. Refer to System Operation and Testing and Adjusting,
“ARD Fuel System - Test”.

ice tool. The electronic service tool enhances the diag- Return the unit to service.
nostics during the service test.
B. Start the engine. Allow the engine to idle for 3 minutes. Repair: Check the list of active diagnostic codes. Trouble-
shoot the code that applies to the failed regeneration. Refer
Do not use the operators switch for a stationary regeneration. to Table 52 for associated codes.
The service tests provide enhanced diagnostics that are nec-
essary for proper troubleshooting and repair. Result: The “Manual DPF Regeneration” did not complete
successfully and there are no associated codes.
C. Start a “Manual DPF Regeneration” in the electronic serv-
ice tool. Proceed to Test Step 7.
7. Replace the ARD Combustion Head ARD Combustion Result: The ARD head was replaced.
Head
A. Replace the ARD combustion head. Refer to Disassembly Proceed to Test Step 8.
and Assembly, “Combustion Head - Remove and Install”.
B. Clean the ARD combustion canister.
(continued)
142 M0070030-01
(Table 54, contd)

8. Perform an ARD Ignition Test ARD Ignition Result: The ARD Ignition Test was successful.
Test
A. Reset all active codes and clear all logged codes. Perform Proceed to Test Step 9.
an ARD Ignition Test. Refer to System Operation and Testing
and Adjusting, “ARD Fuel System - Test”.

ice tool. The electronic service tool enhances the diag- Return the unit to service.
B. Start the engine. Allow the engine to idle for 3 minutes. There are additional codes.
Do not use the operators switch for a stationary regeneration. Repair: Troubleshoot the additional codes before returning
The service tests provide enhanced diagnostics that are nec- the unit to service. Refer to Troubleshooting for the correct
essary for proper troubleshooting and repair. procedure.
C. Start a “Manual DPF Regeneration” in the electronic serv- Verify that the problem is resolved.
ice tool.
i05959017
Battery Problem
Probable Causes
• Battery
• Switched Battery Circuit
Recommended Actions
Download the Product Status Report from the engine
ECM before performing any troubleshooting or
clearing diagnostic trouble codes. Troubleshoot any
M0070030-01 143
Table 55
1.Check the Battery Battery Result: The battery is OK.
A. Verify that the battery is no longer able to hold a charge. Refer Proceed to Test Step 2.
to Systems Operation/Testing and Adjusting, “Battery - Test”.
Result: The battery is not OK.
Repair: Replace the battery. Refer to Disassembly and As-

sembly for the correct procedure.
2. Check the Switched Battery Circuit Switched Result: The switched battery circuit drained the battery by
battery being left in the ON position.
A. Verify that a switched battery circuit drained the battery by circuit
being left in the ON position. Repair: Charge the battery. Verify that the battery is able to
maintain a charge. Refer to Systems Operation/Testing and
Adjusting for the correct procedure.
i06653528
Clean Emissions Module Has

High Oxygen Level
Table 56
Code Description
Aftertreatment #1 Intake O2 : High - The Engine Out NOx Sensor is reading a higher than ex-
3217-16 E1407 (2)
moderate severity (2) pected level of Oxygen (O2).
Aftertreatment #1 Outlet O2 : High - The Tailpipe Out NOx Sensor is reading a higher than ex-
3227-16 E1408 (2)
moderate severity (2) pected level of Oxygen (O2).
The exhaust system is equipped with two sensors

that measure Oxides of Nitrogen (NOx) and Oxygen
(O2). Sensor #1 is mounted in the exhaust pipe
between the engine turbocharger and the Clean
Emissions Module (CEM) and is referred to as the
Engine Out NOx sensor. This sensor monitors the
NOx and O2 coming out of the engine. Sensor #2 is
mounted in the exhaust pipe after the Selective
Catalyst Reduction (SCR) catalyst and is referred to
as the Tailpipe Out NOx sensor. This sensor monitors
the NOx and O2 exiting the SCR cannister.
Follow the troubleshooting procedure to identify the
root cause of the problem.
144 M0070030-01
Table 57
1. Check if NOx Sensors are Installed Correctly Properly In- Result: The sensor is not installed properly.
stalled / Not In-
A. Locate the appropriate NOx Sensor. stalled Properly Repair: Install the sensor properly. Refer to Disassembly
and Assembly, Nitrogen Oxide Sensor - Remove and
B. Check if the sensor is installed properly. Install.
Result: The sensor is installed properly.
2. Check for Exhaust Leaks Exhaust Leaks Result: An exhaust leak was found.
A. Start the engine. Repair: Repair or replace the component causing the
exhaust leak.
B. Check the exhaust system for proper installation.
C. Check for loose or broken exhaust joints.
Result: An exhaust leak was not found.
D. Inspect the exhaust system between the turbocharger outlet
and the tailpipe outlet for signs of an exhaust leak. Proceed to Test Step 3.
3. Perform an Aftertreatment NOx Sensor Functional Test Test Result: The “Aftertreatment NOx Sensor Functional
Test” was successful.
A. Turn the keyswitch to the ON position.
B. Connect to the “Engine #1 Aftertreatment Control ECM” using
the electronic service tool. Result: The “Aftertreatment NOx Sensor Functional
Test” was not successful.
C. Start the engine.
Repair: Replace the failed sensor. Refer to Disassembly
D. Perform an “Aftertreatment NOx Sensor Functional Test” using and Assembly, Nitrogen Oxide Sensor - Remove and
the electronic service tool. Install.
Perform an “Aftertreatment NOx Sensor Functional Test”

using the electronic service tool to verify the repair.
i06245217
Coolant Contains Fuel
Probable Causes
• Leaking injector sleeve and/or damaged seal
M0070030-01 145
Recommended Actions
Table 58
1. Leaking injector sleeve and/or damaged seal Result: The injector sleeve is leaking.
Injector sleeve
A. Remove the valve mechanism covers. Repair: Remove the injector sleeve that is leaking. Carefully
inspect the sleeve for damage. If there are visible signs of
B. Remove the fuel injectors from the cylinder head. damage to the injector sleeve, replace the sleeve. Replace the
O-ring seals for the injector sleeve and reinstall the sleeve. Re-
Refer to the Disassembly and Assembly manual for details. place any damaged components.
Do not allow the pressure on the cooling system to exceed Coolant may also be contaminating the fuel system. After the
103 kPa (15 psi) during the test. Damage to the cooling engine is shut down, the retention of pressure in the cooling
system may result from applying excessive pressure. system may cause the transfer of coolant into the fuel system.
Visually inspect the fuel tank for coolant. The contamination of
C. Pressurize the cooling system in order to identify the injector coolant in the fuel system may damage injectors and other fuel
sleeve that is leaking. Closely inspect the sealing joint around system components. Ensure that all of the fuel system compo-
the top of the injector sleeve. Small amounts of coolant will be nents are in good repair prior to returning the engine to
dripping from the injector sleeve that is leaking. service.
Coolant may also be contaminating the fuel system. After the Do not crank the engine if a cylinder is full of fluid. Cata-
engine is shut down, the retention of pressure in the cooling strophic damage can occur to the engine.
system may cause the transfer of coolant into the fuel system.
Visually inspect the fuel tank for coolant. The contamination of Evacuate all cylinders of fluid before trying to start the engine.
coolant in the fuel system may damage injectors and other fuel
system components. Ensure that all of the fuel system compo-
nents are in good repair prior to returning the engine to service.

steps are listed.
i06245230
Coolant Contains Oil
Probable Causes
• Engine Oil Cooler
• Power Train Oil Cooler (if equipped)

• Water-Cooled Turbocharger
• Cylinder Head Gasket

• Block
The procedures have been listed in order of
Verify the presence of oil in the coolant with a
scheduled oil sample. Verification must be made
before performing the procedure.
146 M0070030-01
Recommended Actions
Table 59
1. Leak in the Engine Oil Cooler Oil Cooler Result: A leak is found in the engine oil cooler.
A. Check for leaks in the engine oil cooler. Refer to Testing Repair: Install a new oil cooler core. Refer to the Disas-
and Adjusting for the proper procedure. sembly and Assembly manual.
Flush the cooling system. Refer to the Operation and

Maintenance Manual for the proper flushing procedure.
Refill the cooling system with the proper coolant. Refer to
the Operation and Maintenance Manual for the correct
coolant and capacities.
Check the oil for coolant. If coolant is found in the oil, drain
the crankcase. Refill the crankcase with the proper oil after
the leak has been repaired. Refer to the Operation and
Maintenance Manual for the correct oil capacities and
viscosity.
Result: A leak was not found in the engine oil cooler.
2. Leak in the Power Train Oil Cooler Power train cooler Result: A leak is found in the power train oil cooler.
A. Check for leaks in the power train oil cooler. Refer to Test- Repair: Install a new oil cooler core. Refer to the Disas-
ing and Adjusting for the proper procedure sembly and Assembly manual.
Flush the cooling system. Refer to the Operation and

Maintenance Manual for the proper flushing procedure.
Refill the cooling system with the proper coolant. Refer to
the crankcase. Refill the oil after the leak has been re-
paired. Refer to the Operation and Maintenance Manual
for the correct oil capacities and viscosity.
Result: A leak was not found in the power train oil cooler.
(continued)
M0070030-01 147
(Table 59, contd)

3. Water-Cooled Turbocharger (if equipped) Turbocharger Result: The turbocharger is cracked.
A. Inspect the turbocharger for cracks. Repair: Replace the turbocharger. Refer to the engine
B. Remove the oil drain line from the turbo and pressurize the
cooling system, Refer to Testing and Adjusting, “Cooling Sys- Flush the cooling system, Refer to the Operation and
tem - Test”. Maintenance Manual for the correct procedure.
C. Check the turbocharger for coolant leakage. Refill the cooling system with the proper coolant. Refer to
the oil. Refill the oil after the leak has been repaired. Refer
to the Operation and Maintenance Manual for the correct
oil capacities.
Result: The turbocharger is not cracked.
4. Cylinder Head Gasket Cylinder head Result: New cylinder head gasket and water seals were
gasket installed.
A. Remove the cylinder head. Refer to the Disassembly and
Assembly manual. Proceed to Test Step 5.
B. Check the cylinder liner projection. Refer to the Systems

Operation/Testing and Adjusting manual.
C. Install a new cylinder head gasket and new water seals in

the spacer plate. Refer to the Disassembly and Assembly
manual.
5. 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 and/or replace the cylin-
on the cylinder head. Refer to System Operation, Testing and der head. Refer to the Disassembly and Assembly
Adjusting for the proper procedure for checking the cylinder manual.
head.
Result: A crack is not found in the cylinder head.
Result: A crack is found in the cylinder block.

6. Cylinder Block Cylinder block
Repair: Repair the cylinder block or replace the cylinder
A. Inspect the cylinder block for cracks. block. Inspect the top deck. Refer to Systems Operation,
Testing and Adjusting, “Cylinder Block - Inspect” for the
proper inspection procedure.
148 M0070030-01

steps are listed.
i06918995
Coolant Level Is Low
Use this procedure to troubleshoot low coolant level

or use this procedure if one of the following codes is
active.

Table 60
J1939 Code Code Description

PDL Code (code descriptions may vary) System Response
The engine has been running for 60 seconds. The engine cool-
ant level has fallen below the coolant level sensor for the
111-1 E2143 (3) Low Engine Coolant Level
specified delay time.
Engine power is derated. The code is logged.
The code is logged.
Engine power is derated. The code is logged.
Probable Causes
• Low coolant level
• Coolant system leak

• NOx Reduction System (NRS) Cooler leak
• Air in cooling system

• Combustion gases in cooling system
• Aftertreatment Regeneration Device (ARD) nozzle
heater leak
• Incorrect antifreeze mixture
• Coolant level sensor
Recommended Actions
steps are listed.
M0070030-01 149
Table 61
1. Check for Low Coolant Level. Coolant Result: The engine coolant level is OK.
Level
A. Inspect the coolant level. Proceed to Test Step 7.
Result : The engine coolant level is NOT OK.
Repair : Fill the coolant tank to the proper level if necessary.
2. Check the Cooling System for Leaks. Cooling Result : The cooling system is OK.
system
A. Check the cooling system for leaks. Refer to Systems Opera- Proceed to Test Step 3.
tion, Testing and Adjusting, Cooling System - Inspect and Systems
Operation, Testing and Adjusting, Cooling System - Test. Result: The cooling system is NOT OK.
Repair: Refer to Systems Operation, Testing and Adjusting,

“Cooling System - Test” for the correct procedure. Repair
any leaks immediately.
If the problem is not resolved, proceed to Test Step 3.
3. Check the NRS Cooler for Leaks. NRS Cooler Result : The NRS cooler is OK.
A. Check the NRS cooler for leaks. Refer to Systems Operation, Proceed to Test Step 4.
Testing and Adjusting, Exhaust Cooler (NRS) - Test.
Result : The NRS cooler is NOT OK.
Repair : Refer to Testing and Adjusting, “Exhaust Cooler

(NRS) - Test”.
4. Check for Air or Combustion Gas in the Cooling System. Cooling Result : The cooling system is OK.
system
Result : There is air in the cooling system.
Repair : Refer to Systems Operation/Testing and Adjusting,

“Testing the Cooling System” for the correct procedure.
Result : There are combustion gases in the cooling system.
Repair : Inspect the cylinder head gasket for leakage and

contact the Dealer Solution Network (DSN) for further
assistance.
(continued)
150 M0070030-01
(Table 61, contd)

5. Check for Leakage at the ARD Nozzle Heater O-rings. ARD nozzle Result : The ARD nozzle heater o-rings are OK.
heater o-
Note : White exhaust smoke would be an indication of leakage rings Proceed to Test Step 5.
past the ARD nozzle heater o-rings.
Result : The ARD nozzle heater o-ring seals are NOT OK.
Repair : To check for leakage at the ARD nozzle heater o-

rings, pressurize the cooling system and then remove the
ARD head. Inspect the combustion chamber for signs of
coolant. If the o-rings are leaking coolant, replace the ARD
head.
6. Check for the Correct Mixture of Antifreeze and Water. Antifreeze Result : The antifreeze and water mixture is OK.
mixture
A. Check for the correct mixture of antifreeze and water. Refer to Proceed to Test Step 7.
the Operation and Maintenance Manual for more information.
Result : The antifreeze and water mixture is NOT OK.
Repair : Refer to the Operation and Maintenance Manual.

7. Check for a Faulty Coolant Level Sensor Coolant Lev- Result: The coolant level sensor is not operating properly.
el Sensor
A. If an electrical problem with the coolant level sensor is sus- Repair: Replace the coolant level sensor.
pected, refer to Troubleshooting, “Coolant Level - Test”.
i06657248
Coolant Pressure Is Low
Use this procedure to troubleshoot the coolant flow or

coolant pressure switch. Use this procedure if any of
the diagnostic codes in Table 62 are active or easily
repeated.
Table 62
Diagnostic Codes Table

PDL Code (code descriptions may vary) Comments
E563 (3) Low Engine Coolant Flow The ECM detects that the coolant
flow through the engine is lower
than expected.
1937-2 Engine Coolant Flow Switch : Er- The ECM detects that the coolant
ratic, Intermittent, or Incorrect flow through the engine is differ-
ent than expected.
(continued)
M0070030-01 151
(Table 62, contd)


109-17 E2112 (1) Engine Coolant Pressure : Low - The engine coolant pressure is
least severe (1) lower than expected for an ex-
tended period. The code is
logged.
moderate severity (2) lower than expected for an ex-
logged.
most severe (3) lower than expected for an ex-
logged.

steps are listed.
Table 63
1. Verify the Coolant Level Coolant Level Result: The coolant level is correct.
A. Verify that the coolant is filled to the correct level. If the Proceed to Test Step 2.
coolant level is too low, air will get into the cooling system.
Air in the cooling system will cause a reduction in coolant Result: The coolant level is not correct.
flow and pressure.
Repair: Determine the cause of the low coolant level. Refer to
B. Check the cooling system for coolant leaks. Troubleshooting, “Coolant Level Is Low”. Verify that the prob-
lem has been corrected.
2. Check the Cooling System Hose Routing Leaks or Kinks Result: The coolant clamps and hoses are installed properly.
A. Check that the cooling system clamps and hoses are in- Proceed to Test Step 3.
stalled in the proper location and the clamps are tight.
Result: The coolant clamps and hoses are not installed
B. Ensure that there are no kinks or tight bends that may properly.
cause excessive restriction.
Repair: Repair or replace the damaged cooling system com-
C. Check to make sure that the hoses are routed correctly. ponent. Verify that the problem has been corrected. Return
the unit to service.
(continued)
152 M0070030-01
(Table 63, contd)

3. Check the Expansion Tank (if equipped) Shunt Line Result: The shunt line is properly installed and there are no
restrictions.
A. Check the shunt line for a restriction. A restriction of the
shunt line from the expansion tank to the inlet of the jacket For a E2112 or 109 code, proceed to Test Step 4.
water pump will cause a reduction of water pump
efficiency. For a E563 or 1937 code, proceed to Test Step 5.
B. Inspect the expansion tank for a restriction that blocks Result: The shunt line is not properly installed or there are
the port to the shunt line. restrictions.
Note: The expansion tank may be integrated into the de- Repair: Install the shunt line correctly or replace the line if
sign of the radiator top tank and may not be separate. necessary. Remove any restrictions that are found.
Verify that the problem has been corrected. Return the unit to
service.
4. Check the Coolant Pressure Sensor For Accuracy Coolant Pressure Result: The pressure difference between the mechanical
Sensor gauge and the reading in the electronic service tool is less
A. Install a mechanical pressure gauge in the coolant jack- than 14 kPa (2 psi).
et near the coolant pressure sensor.
B. Start the engine.
Result: The pressure difference between the mechanical
C. Connect to the engine ECM using the electronic service gauge and the reading in the electronic service tool is greater
tool. than 14 kPa (2 psi).
D. Allow the engine to run and record the pressure on the Repair: Replace the coolant pressure sensor.
mechanical gauge.
E. Check the pressure reading at various engine speeds. service.
5. Check the Coolant Flow Switch Coolant Flow Result: The coolant flow switch status changed in the elec-
Switch tronic service tool when the paddle was rotated.
A. Remove the coolant flow switch from the engine.
B. Turn the keyswitch to the ON position.
Result: The coolant flow switch status did not change in the
C. Connect to the engine ECM using the electronic service electronic service tool when the paddle was rotated.
tool.
A failed coolant flow switch has been detected.
D. Rotate the paddle on the end of the coolant flow switch.
Repair: Replace the coolant flow switch.
E. Monitor the status of the coolant flow switch in the elec-
tronic service tool. Verify that the problem has been corrected. Return the unit to
service.
(continued)
M0070030-01 153
(Table 63, contd)

6. Check the Water Pump Damaged Impeller Result: The water pump impeller is not damaged or loose and
there are no restrictions.
A. Remove the water pump and check for a damaged or
loose impeller, or a restriction in the water pump inlet or Proceed to Test Step 7.
outlet ports.
Result: The water pump impeller is damaged or loose, or
there are restrictions.
Repair: Replace the water pump.
service.
7. NRS Cooler Leak NRS Cooler Result: The NRS cooler does not have a leak.
A. Check the NRS cooler for leaks. Refer to Testing and Proceed to Test Step 8.
Adjusting, “Exhaust Cooler (NRS) - Test”.
Result: The NRS cooler has a leak.
Repair: Replace the NRS cooler. Refer to the Disassembly

and Assembly manual for the related procedure.
service.
8. Check the Radiator or Heat Exchanger Restrictions Result: There were deposits or restrictions in the radiator or
heat exchanger.
A. Check the radiator or heat exchanger for a restriction.
Check internally for dirt, debris, or deposits on the radiator Repair: Clean or replace the radiator or heat exchanger.
core.
service.
Result: There were no deposits or restrictions in the radiator

or heat exchanger.
9. Check the Oil Cooler Restrictions Result: There was debris or restrictions in the oil cooler.
A. Check the inlet side of the oil cooler for debris or Repair: Clean or replace the oil cooler.
blockage.
service.
154 M0070030-01
If the procedure did not correct the issue, contact the

Dealer Solutions Network (DSN).
i06658232
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
event codes. Access the monitoring system on the
electronic service tool to view the current trip points
for these codes.
Table 64

The engine coolant temperature has exceeded the trip point
Engine Coolant Temperature High - and the delay time has expired.
110-0 E361(3)
Most Severe (3) Engine power is derated.
The code is logged.

Engine Coolant Temperature High-
110-15 E361(1) and delay time has expired.
Least Severe (1)
The code is logged.

High Engine Coolant Temperature
110-16 E361(2) and the delay time has expired.
High - Moderate Severity (2)
The code is logged.
Probable Causes
• Low Coolant Level and/or Coolant Leakage
• Coolant Temperature Sensor
• Water Temperature Regulator and/or Pressure

Relief Valve
• NOx Reduction System (NRS) Cooler Leak

• Radiator
• Heat Exchanger
• Engine Cooling Fan (if equipped)
• Coolant Pump
• Cylinder Head Gasket
Recommended Actions
steps are listed.
M0070030-01 155
Table 65
1. Coolant Level Engine Cool- Result: The engine coolant level is OK.
ant Level
A. Check the coolant level. Proceed to Test Step 2.
Result: The engine coolant level is not OK.
Repair: Check the cooling system for leaks. Refer to Trou-

bleshooting, “Coolant Level is Low” for additional informa-
tion. Repair any leaks immediately.
2. Coolant Temperature Sensor and/or the Circuit Coolant Tem- Result: The temperature sensor is working properly.
perature
A. Check the reading of the coolant temperature on the electronic Sensor Proceed to Test Step 3.
service tool. The temperature should rise steadily as the engine is
warmed. Ensure that the temperature is reasonable. Result: The temperature sensor is not working properly.
Repair: Troubleshoot the circuit and the coolant tempera-

ture sensor. Refer to Troubleshooting, “Sensor Signal
(Analog, Passive) - Test”.
3. Water Temperature Regulator and/or Pressure Relief Valve Temperature Result: The pressure relief valve and/or the water temper-
Regulator ature regulator are operating properly.
A. Pressure-test the cooling system. Refer to Systems Operation,
Testing and Adjusting, Cooling System - Test for the correct Proceed to Test Step 4.
procedure.
Result: The pressure relief valve and/or the water temper-
B. Check that the seating surfaces of the pressure relief valve and ature regulator are not operating properly.
the radiator cap are clean and undamaged.
Repair: Clean the components and/or replace the
C. Check operation of the pressure relief valve and/or the water components.
temperature regulator.
4. NRS Cooler Leak NRS Cooler Result : The NRS cooler has a leak.
A. Check the NRS cooler for leaks. Refer to Systems Operation, Repair: Replace the NRS cooler. Refer to the Disassem-
Testing and Adjusting, “Exhaust Cooler (NRS) - Test”. bly and Assembly manual for the related procedure.
Result : The NRS cooler does not have a leak.
(continued)
156 M0070030-01
(Table 65, contd)

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

Exchanger
A. Check for sufficient flow and temperature of the cooling water Proceed to Test Step 7.
through the heat exchanger.
Result : The flow of cooling water is not sufficient.
Repair: Determine the location of the obstruction. If the

temperature of the cooling water is too high, determine the
cause. Ensure that the size of the heat exchanger is suffi-
cient. Make the necessary repairs.
7. Faulty Engine Cooling Fan (if equipped) Fan Belt or Result : The fan belt is tensioned correctly.
Clutch
A. If the fan is belt driven, check for loose drive belts. Proceed to Test Step 8.
A loose fan drive belt will cause a reduction in the air flow across Result : The fan belt is not tensioned correctly.
the radiator.
Repair: Adjust the tension of the fan drive belt, if neces-
B. Check the fan clutch, if equipped. sary. Refer to Operation and Maintenance Manual.
A fan clutch or a hydraulic driven fan that is not turning at the cor- Result : The fan clutch is operating correctly.
rect speed can cause improper air speed across the radiator core.
The lack of proper air flow across the radiator core can cause the Proceed to Test Step 8.
coolant not to cool to the proper temperature differential.
Result : The fan clutch is not operating correctly.
Repair: Refer to Troubleshooting, “Cooling Fan Control -

Test” for troubleshooting information.
(continued)
M0070030-01 157
(Table 65, contd)

8. Inspection of the Coolant Pump Coolant Pump Result : The coolant pump is operating correctly.
A. Inspect the impeller of the coolant pump for damage and/or Proceed to Test Step 9.
erosion.
Result : The coolant pump is not operating correctly.
B. Make sure that the drive gear is not loose on the drive shaft of
the coolant pump. Repair: If necessary, replace the coolant pump. Refer to
Result : The cylinder head was checked for leaks and the
9. Cylinder Head Gasket Head Gasket gasket was replaced.
A. Remove the cylinder head. Refer to Disassembly and Assem- Verify that the problem was corrected.
bly, Cylinder Head - Remove.
B. Check the cylinder liner projection. Refer to Systems Operation,

Testing and Adjusting, Cylinder Liner Projection - Inspect.
C. Pressure test the head for leaks.
D. Install a new cylinder head gasket and new water seals in the
spacer plate. Refer to the Disassembly and Assembly manual.
i06658282
Coolant Temperature Is Low
Use this procedure to troubleshoot a low coolant

temperature. Refer to Troubleshooting, “Event
Codes” for information about event codes.
Table 66
Code Description
Engine Coolant Temperature : Low - The coolant temperature did not rise above 65° C (149° F)
110-17 E199 (1)
least severe (1) after an extended period of operation under load.
Probable Causes
• Thermostat
Personal injury can result from hot coolant,
• Coolant temperature sensor steam and alkali.
At operating temperature, engine coolant is hot
• Extreme ambient temperatures and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
• Engine cooling fan configuration steam. Any contact can cause severe burns.
Recommended Actions Remove filler cap slowly to relieve pressure only

when engine is stopped and radiator cap is cool
Note: The procedures have been listed in order of enough to touch with your bare hand.
Cooling System Conditioner contains alkali.
Avoid contact with skin and eyes.
158 M0070030-01

steps are listed.
Table 67
1. Make Sure the Engine is Properly Equipped for Ambient Engine Operation Result: The engine is equipped for the ambient
Conditions conditions.
A. Ensure that the engine is properly equipped for the ambient con- Proceed to Test Step 2.
ditions. Refer to the Operation and Maintenance Manual for opera-
tion in cold ambient 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.
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.
Repair: Check the cooling system for leaks. Refer to

Troubleshooting, “Coolant Level is Low” for additional
information. Repair any leaks.
3. Faulty Coolant Temperature Sensor Faulty Coolant Result The coolant temperature is not reasonable.
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 reasonable.
Result The coolant temperature is reasonable.
4. Check the Engine Coolant System Coolant Result: The coolant temperature comes up to opera-
Temperature tional temperature and the engine fan is functioning
A. Turn the keyswitch to the OFF position. properly.
B. Connect to the electronic service tool. Return the unit to service.
C. Start the engine. Result The coolant temperature does not come up to
operational levels and the engine fan is functioning
D. Monitor the “Engine Coolant Temperature” in the status screen properly.
E. Ensure the engine cooling fan is properly configured for the am- Repair: A failed thermostat has been detected. Re-
bient conditions. place the thermostat.
F. Ensure that the engine cooling fan is operation properly. Result The coolant temperature does not come up to
operational levels due to the engine fan running
continuously.
Repair: Refer to Troubleshooting, “Cooling Fan Is Al-

ways ON”.
M0070030-01 159
i06245307
Cooling Fan Is Always ON
Probable Causes
• Operation of the Cooling Fan
160 M0070030-01
Recommended Actions
Table 68
1. Check the Operation of the Cooling Fan Cooling fan Result: The parameter is not programmed to allow the fan
parameters to operate.
and the Electronic Control Module (ECM). Refer to Troubleshoot- Repair: The ECM is not controlling the cooling fan. Refer to
ing, “Electronic Service Tools”, if necessary. the troubleshooting information for the application in order to
troubleshoot the cooling fan.
B. Check the value of the fan control parameters.
Result: The parameter is programmed to allow the fan to
operate.
Repair: The ECM is controlling the cooling fan. Refer to

Troubleshooting, “Cooling Fan Control - Test” in order to
troubleshoot the cooling fan.

steps are listed.
i06658292
Crankcase Fumes Disposal

Tube Has Oil Draining
Probable Cause
Left side of the engine
(5) Check valve
(1) Crankcase pressure sensor
(2) Crankcase filter housing (if equipped)
(3) Fumes disposal tube
(4) Oil drain tube
M0070030-01 161
Recommended Actions
Table 69
1. Check Valve Check valve Result: The check valve was replaced.
The check valve at the bottom of the oil drain tube has failed. Verify the repair.
A. Replace check valve (5).

steps are listed.
i06658294
Crankcase Pressure Is High
The engine is equipped with an open crankcase

ventilation (OCV) system. Refer to Illustration 67 .
The pressure sensor monitors the level of crankcase
pressure. The OCV system contains a filter element
(if equipped). Tubing routes the blowby from the OCV
system to the filter housing (if equipped). The filter
housing (if equipped) contains a filter element. The
filter element filters the blowby. Refer to the
Operation and Maintenance Manual for the
replacement of the filter.
Troubleshooting Procedure
Reset all active codes and clear all logged codes.
Use this procedure to troubleshoot a high crankcase
pressure or use this procedure if one of the following
diagnostic codes is active.
Table 70
J1939 Description
Code
The Engine Control Module (ECM) activates this code when the crankcase pres-
sure has exceeded the limit for a programmed time period. The amber warning
Engine Crankcase Pressure : lamp is illuminated. The code is logged. Engine power is derated.
101-15 E1036 (1)
High - Least Severe
This code can be caused by an obstructed tube, an obstructed filter (if equipped),
or an obstructed hose. Also, a plugged OCV system will cause the code.
The ECM activates this code when the crankcase pressure has exceeded the limit
for a programmed time period. The amber warning lamp is illuminated. The code
is logged. Engine power is severely derated.
Engine Crankcase Pressure :
101-16 E1036 (2)
High - Moderate Severity
This code can be caused by an obstructed tube, an obstructed filter (if equipped),
or an obstructed hose.
Also, a plugged OCV system will cause the code.
162 M0070030-01
• Worn engine components
Recommended Actions
steps are listed.
(2) Crankcase filter housing (if equipped)
(4) Oil drain tube
(5) Check valve
Probable Causes
• Engine oil level
• Plugged OCV system
• Faulty check valve

• Faulty sensor
M0070030-01 163
Table 71
1. Check the Engine Oil Level Engine Oil Result: The engine oil level is OK.
Level
A. Check the engine oil level. Proceed to Test Step 2.
Result: The engine oil level is high.
Repair: Troubleshoot the cause of the incorrect oil level.
2. Plugged OCV System Plugged Result: The OCV is plugged.

OCV
A plugged OCV system will cause excessive crankcase pressure. Repair: Replace the fumes disposal filter (if equipped) ac-
cording to the Operation and Maintenance Manual, “Fumes
A. Check the OCV for plugging. Disposal Filter Element - Replace”.
Result: The OCV is not plugged.
3. Faulty Check Valve Check Valve Result: The check valve was replaced.
A faulty check valve can cause excessive crankcase pressure. A Verify that the problem is resolved.
faulty check valve will not allow the crankcase to vent properly.
If the problem is not resolved, Proceed to Test Step 4.
A. Replace the check valve.
4. Plugged Oil Disposal Tube Plugged Oil Result The oil disposal tube is obstructed.
Disposal
A plugged disposal tube will not allow the crankcase to vent Tube Repair: Clean any obstructions from the tube.
properly.
Result The oil disposal tube is not obstructed.
A. Check the disposal tube for obstructions.
(continued)
164 M0070030-01
(Table 71, contd)

5. Faulty Sensor Crankcase Result The crankcase pressure reading is 0 kpa ± .5 kpa .
Pressure
A. Connect the electronic service tool to the service tool Sensor Proceed to Test Step 6.
connector.
Result The crankcase pressure reading is not 0 kpa ± .5 kpa
B. Turn the keyswitch to the ON position. Do not start the engine. .
Remove the oil filler cap. Repair: Replace the crankcase pressure sensor.
Monitor the crankcase pressure in the electronic service tool.
6. Internal Engine Problem Damaged or Result There are worn or damaged engine parts.
Worn Engine
Damaged pistons or rings can cause too much pressure in the Parts Repair: Repair or replace the worn or damaged parts.
crankcase. This condition will cause the engine to run rough.
There will be more than the normal quantity of fumes (blowby) en-
tering the OCV system. The OCV system can then more quickly
become restricted, causing oil leakage at gaskets and seals that
would not normally have leakage. Blowby can also be caused by
worn valve guides or by a failed turbocharger seal.
A. To determine whether the piston rings leak, measure the crank-

case blowby. Refer to Systems Operation, Testing and Adjusting,
Engine Crankcase Pressure (Blowby) - Test.
i06659286
Crankcase Pressure Is Low

trouble code:
Note: The following code may not be applicable for

certain applications.
Table 72
J1939 PDL Description

Code Code
The Engine Control Module (ECM) activates this code when the crankcase
pressure has been below the minimum value for a programmed time period.
- E994 (2) Low Crankcase Pressure
The amber warning lamp is illuminated. The code is logged. Engine power is
derated.
M0070030-01 165
• The tube between the breather and the breather

canister (if equipped) is not connected.
The engine is equipped with an open crankcase
ventilation system.
Typical crankcase ventilation system
(2) Breather
(3) Filter housing (if equipped)
(5) Check valve
Probable Causes
• The oil fill cap is off.
• The oil level gauge (dipstick) is not fully seated.
• The vent filter (if equipped) for the crankcase is

not installed.
166 M0070030-01
Recommended Actions
Table 73
1. Engine Ventilation Ventilation Result: The probable cause was found.
A. Establish communication between the electronic service tool Repair: Make the necessary repairs.
and the ECM . Refer to Troubleshooting, “Electronic Service
Tools”, if necessary. Reset all active codes and clear all logged codes. Use the
electronic service tool to verify that the problem is resolved.
B. Inspect the engine. Look for the conditions that are listed
above.
i06245465
Cylinder Is Noisy
Probable Causes
• Active codes and logged codes
• Low quality fuel
• Injectors
• Lack of lubrication
• Valve train components

• Gear train and components of the lower end
Recommended Actions
M0070030-01 167
Table 74
1. Active Codes and Logged Codes Codes Result: A diagnostic trouble code is not active or logged.
A. Establish communication between the electronic service tool Proceed to Test Step 2.
and the Electronic Control Module (ECM).
Result: A diagnostic trouble code is active or logged.
Repair: Troubleshoot the active or logged codes.
2. Low Quality Fuel Fuel Result: The fuel quality is OK.
A. Refer to Operation and Maintenance Manual for information on Proceed to Test Step 3.
the proper characteristics of the fuel for the engine. If necessary,
obtain a fuel analysis in order to confirm that the correct fuel is Result: The fuel quality is not OK.
being used for the engine. Refer to Systems Operation/Testing and
Adjusting, “Fuel System Quality Test” for the proper procedure. Repair: Replace the fuel. Verify that the repair eliminated
the problem.
3. Injectors Injector Sole- Result: The test was successful.

noid Test or
Cylinder Cut- Proceed to Test Step 4.
A. Perform the “Injector Solenoid Test” on the electronic service out Test
tool in order to determine if all of the injector solenoids are being Result: The test was not successful.
energized by the ECM.
Repair: Diagnose the problem and then repair the
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests” problem.
under the “Diagnostics” menu.
C. Perform the “Automatic Cylinder Cutout Test” on the electronic
service tool. Verify that the repair eliminated the problem.
4. Lack of Lubrication Lubrication Result: The oil passages are not blocked and the engine
has proper lubrication.
A. Check for proper lubrication of the valve components. Check for
sufficient lubrication between the injector tappets and the rocker Proceed to Test Step 5.
arms.
Result: The oil passages are blocked or the engine does
B. Check for blocked oil passages. Oil passages must be clean. not have proper lubrication.
Clean any oil passages that are questionable. Refer to the Disas-
sembly and Assembly for additional information. Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
(continued)
168 M0070030-01
(Table 74, contd)

5. 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 6.
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 for Repair: Make the necessary repairs, Verify that the repair
damage: eliminated the problem.
1. Camshaft
2. Valve rotocoil
3. Valve springs
4. Camshaft followers
5. Rocker shaft
6. Bridges
7. Pushrods
8. 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 the Disassembly and Assembly for additional information.
6. Gear Train and Components of the Lower End Gear train Result: The gear train or lower end components are
damaged.
A. Inspect the gear train and lower end components.
Repair: Replace any damaged parts.

steps are listed.
i06659304
DEF Control Module

Temperature Is High
Use this procedure if one of the following event codes

are active. Refer to Troubleshooting, “Event Codes”
for information about event codes. For information on
the engine monitoring system, refer to
Troubleshooting, “Engine Monitoring System”.
M0070030-01 169
Table 75
Code Description
The temperature of the Diesel Exhaust Fluid Control

Aftertreatment 1 Diesel Exhaust Fluid Controller Tem-
5480-16 E1430 (2) Unit (DCU) has exceeded the trip point of 116° C
perature : High - moderate severity (2)
(240° F).

steps are listed.
170 M0070030-01
Table 76
1. Determine the Source of the High Temperature Heat Source Result: The DCU is located close to a heat source.
A. Evaluate the installation location of the DCU. Repair: Eliminate the heat source by installing a heat
shield or moving the component creating the heat.
B. Check for heat sources close to the DCU.
DCU
2. Replace the DCU Result: The DCU was replaced.
A. Replace the DCU. Verify that the problem is resolved.
i06659311
DEF Does Not Purge
Table 77
J1939 Code Description

PDL Code Comments
Code
Aftertreatment 1 Diesel Exhaust
The DEF system did not completely purge after the engine was turned OFF.
3362-14 E114 (1) Fluid Dosing Unit Input Lines :
The code is logged.
Special Instruction
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 78
Associated Codes
J1939 Code PDL Code
4374-5 3118-5
4374-6 3118-6
4334-16 E930 (2)
4376-5 3862-5
4376-6 3862-6
5966-6 3965-6
6309-6 3966-6
M0070030-01 171

steps are listed.
Table 79
1. Review the “ Aftertreatment Abnormal Shutdown History”” in DEF Pump Result: The system was not allowed 2 minutes to purge
the Electronic Service Tool before the battery disconnect was turned to the OFF
position.
A. Connect to the Engine #1 Aftertreatment Controller using the
electronic service tool. Inform the operator to wait 2 minutes after key-off before
turning the battery disconnect to the OFF position.
B. Proceed to “Aftertreatment Abnormal Shutdown History” . Se- Return the unit to service.
lect the “Information” tab, then select the “History” tab in the elec-
tronic service tool. Result: The system was allowed 2 minutes to purge be-
fore the battery disconnect was turned to the OFF
C. Review the engine shutdown type for cold shutdown position.
occurrences.
D. If the “Aftertreatment Abnormal Shutdown History” shows that
the system was not allowed the full 2 minutes to purge, inform the
operator to wait 2 minutes after key-off before turning the battery
disconnect to the OFF position.
2. Check for Associated Diagnostic Trouble Codes Diagnostic Trou- Result: An associated diagnostic trouble code is
ble Code present.
A. Connect to the Engine #1 Aftertreatment Controller using the
electronic service tool. Repair: Troubleshoot the associated code.
B. Check for associated diagnostic trouble codes.
i06919005
DEF Module Does Not

Respond

codes:
Features” for more information about service
features.
Table 80
Code Description
Aftertreatment #1 Diesel Exhaust Flu-

3361-7 3821-7 id Dosing Valve Actuator: Not Re- The DEF injector is not functioning properly.
sponding Properly

3361-11 3821-11 id Dosing Valve Actuator : Other Fail- There is a short circuit in the DEF injector wiring.
ure Mode
3361-14 3821-14 id Dosing Valve Actuator : Special The DEF injector is not functioning properly.
Instruction
172 M0070030-01
Table 81
Required Tools
Tool Part Number Part Description Qty
A T400241 Probe - Female 2

B T400240 Probe - Male 2
C T4000236 Kit - Test 1
Table 82
1. Check the Resistance of the DEF Injector Ohms Result : The resistance of the DEF injector measured be-
tween 10 Ohms to 14 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 to 14 Ohms. A failed DEF injector
C. Inspect the connector for damage or debris. has been detected.
D. Connect Tooling (A) to the DEF injector. The connectors must Repair : Replace the failed DEF injector. Refer to the Dis-
be used to prevent damage to the DEF injector connector. assembly and Assembly manual for the correct
procedure.
E. Measure the resistance of the DEF injector.
2. Check for a Short Circuit in the Wiring Harness Ohms Result : The resistance of the DEF injector wiring har-
ness measured greater than 10K Ohms.
A. Disconnect the injector from the applicable harness.
Repair : Connect the injector to the applicable harness.
B. Connect Tooling (B) to the DEF injector harness connector.
The connectors must be used to prevent damage to the DEF in- Proceed to Test Step 3.
jector connector.
Result : The resistance of the DEF injector wiring har-
C. Measure the resistance between the DEF injector positive wire ness did not measure greater than 10K Ohms.
and the DEF injector negative wire at the DEF injector connector.
Repair : There is a short circuit in the wiring harness be-
Note : The reading will measure the resistance in the wiring har- tween the DEF injector connector and the DCU. Repair or
ness between the DEF injector connector and the DCU. replace the wiring harness. Connect the injector to the ap-
plicable harness.
3. Check the Diesel Exhaust Fluid (DEF) Quality. DEF Result : The DEF is not contaminated.
A. Measure the DEF quality. Refer to Testing and Adjusting, “Die- Proceed to Test Step 4.
sel Exhaust fluid Quality - Test” for the correct procedure.
Result : The DEF is contaminated.
Repair : Contact the Dealer Solutions Network (DSN) for

further information.
(continued)
M0070030-01 173
(Table 82, contd)

4. Perform the “ DEF Dosing System Accuracy Test”” Using the DEF Dosing Result : The quantity collected is below 100 mL (3.4 oz).
Electronic Service Tool System Accu-
racy Test Proceed to Test Step 5.
A. Refer to Systems Operation, Testing and Adjusting, “Aftertreat-
ment SCR System Dosing - Test” for the correct procedure. Result : The quantity collected is within the desired
range. The desired range is 100 mL (3.4 oz) minimum to
130 mL (4.4 oz) maximum.
Result : The quantity collected is above the maximum

130 mL (4.4 oz). A failed DEF injector has been
detected.
Repair : Replace the DEF injector, refer to the Disassem-

bly and Assembly manual for more information.
5 Check the DEF Pressure Line Restriction, Ob- Result : An obstruction was found.
structions, and
A. Turn the keyswitch to the OFF position. Allow 2 minutes to Leaks Repair : Flush or replace the line.
elapse before proceeding.
B. Visually inspect the lines for leaks or damage.
Result : An obstruction was not found.
C. Remove the DEF pressure line between the DEF pump and
the DEF injector. Refer to the Disassembly and Assembly manual Proceed to Test Step 6.
for the correct procedure.
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 replaced.
A. Turn the keyswitch to the OFF position. Proceed to Test Step 7.
B. Refer to the Disassembly and Assembly manual for the correct

procedure.
Note : Do not install the new injector until Test Step 7 has been
completed.
(continued)
174 M0070030-01
(Table 82, contd)

7. Perform the DEF Dosing System Accuracy Test Electronic serv- Result: The quantity collected is within the desired range
ice tool test (Min. 100 ml, Max. 130 ml).
A. Perform a “DEF Dosing System Accuracy Test” using the elec-
tronic service tool. Refer to Testing and Adjusting, “Aftertreatment Proceed to Test Step 8.
SCR System Dosing Test” for the correct procedure.
Result: The quantity collected is not within the desired
range (Min. 100 ml, Max. 130 ml).
Repair : Replace the DEF pump. Refer to the Disassem-

bly and Assembly manual for the correct procedure.
8. 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. Connect to the electronic service tool. Result : The test not was successful and more codes
were logged.
C. Perform an “Aftertreatment System Functional Test” using the
electronic service tool. Repair : Troubleshoot the additional codes, refer to Trou-
bleshooting, Event Codes Troubleshooting, Diagnostic
D. Download a warranty report. Refer to “Aftertreatment Abnormal Trouble Codes and for the correct procedure.
Shutdown History” under the “Information” tab in the “Engine #1
Aftertreatment Controller” .
Note : If hot shutdowns have occurred, communicate the need to

allow the engine to cool before shutting down the machine.
i06660544
DEF Pressure Is High
Table 83

PDL Code Comments
Code

The DCU detects that the DEF pump pressure is above the acceptable range.
4334-16 E930 (2) Fluid Doser Absolute Pressure :
The code is logged.
M0070030-01 175
(1) Backflow line connection at DEF Header (2) Backflow line connection at DEF Pump

steps are listed.
176 M0070030-01
Table 84
1. Check the Backflow Line for a Restriction Restriction Result: An obstruction was found.
A. Turn the keyswitch to the OFF position. Allow 2 minutes to Repair: Flush the line or replace the line.
B. Remove the backflow line from the DEF header and the DEF
pump. Result: An obstruction was not found.
C. Inspect the backflow line for obstructions. Flush line with water/ Proceed to Test Step 2.
low pressure air if necessary.
Possible obstructions are ice, DEF deposits, or debris.
2. Replace the Backflow Fitting Replace Back- Result: The fitting was replaced.
flow Fitting
A. Replace the backflow fitting on the DEF pump. Refer to the Dis- Proceed to Test Step 3.
assembly and Assembly manual for the correct procedure.
3. Check for a Restriction in the DEF Pump DEF Present Result: DEF did not flow from the DEF backflow line into
the container.
A. Reinstall the backflow line onto the DEF pump. Place the other
end of the line into a bucket or beaker to collect the DEF. Repair: Replace the DEF pump and reinstall all DEF
lines. Refer to the Disassembly and Assembly manual for
B. Turn the keyswitch to the ON position. Do not start the engine. the correct procedure.
C. Connect to the “Diesel Exhaust Fluid Controller #1 ECM” in the Proceed to Test Step 4.
Result: DEF flowed from the backflow line into the
D. Perform the “DEF Dosing System Verification Test” . Refer to container.
Troubleshooting, “Service Tool Features” for more information.
Repair: Reinstall the backflow line onto the DEF header.
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 “Engine #1 Aftertreatment Controller” in the Result: The test was not successful. There are additional
electronic service tool. codes.
C. Perform the “Aftertreatment System Functional Test” . Repair: Troubleshoot the additional codes. Refer to Trou-
bleshooting for the correct procedure. Verify that the
problem is resolved.
M0070030-01 177
i06919008
DEF Pressure Is Low
Table 85
Code Description
DEF pump pressure is not stable after the initial priming

sequence.
Aftertreatment 1 Diesel Exhaust Fluid
OR
4334–7 3090–7 Doser Absolute Pressure : Not Re-
The DEF pump is not able to supply DEF after the line heaters
sponding Properly
have been energized and a heating cycle has been
completed.
Aftertreatment #1 DEF Doser abso-

Diesel Exhaust Fluid (DEF) system pressure dropped below
4334-18 E931 (2) lute Pressure : Low - moderate se-
the acceptable threshold during dosing
verity (2)
Aftertreatment Diesel Exhaust Fluid

5392-31 E1370 (2) DEF system pressure was not achieved during priming
Dosing Unit Loss of Prime
Table 86
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. The cap contains a membrane so care must be
taken not to damage the membrane. If the cap cannot be
B. Remove and inspect the filler cap for blockages. cleaned, replace the cap.
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.
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)
178 M0070030-01
(Table 86, contd)

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 10.
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.
4. 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.
B. Connect to the “Aftertreatment Diesel Exhaust Fluid Control-
ler #1” using the electronic service tool. Result: A leaking or disconnected line was not found.
C. Navigate to “Diagnostics Tests” . Proceed to Test Step 5.
D. Perform the “DEF Dosing System Verification Test” to pres-

surize the system.
E. Inspect all DEF lines from the tank to the DEF injector. Check
for pinched, damaged, disconnected, or leaking lines.
F. Turn the keyswitch to the OFF position.
M0070030-01 179
(1) DEF Suction Line Connection on the

Header Unit
180 M0070030-01
Table 87
5. Check the DEF Quality DEF Result : The DEF is not contaminated.
A. Measure the DEF quality. Refer to Testing and Adjusting, “Diesel Proceed to Test Step 6.
Exhaust Fluid Quality - Test” for the correct procedure.

6. 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 10.
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.
M0070030-01 181
(2) DEF suction line filter fitting (3) DEF pump (4) DEF pump filter cap
Table 88
7. Replace the DEF Pump Filters DEF Pump Result : The DEF pump filters were replaced.
Filters
A. Clean the area around the pump filters. Proceed to Test Step 8.
B. Replace the DEF pump suction line filter fitting and DEF pump
filter. Refer to Illustration 74 . Also, refer to the Disassembly and
Assembly manual for the correct procedure.
182 M0070030-01
(5) DEF Pressure
Table 89
8. 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.
B. Connect to the “Aftertreatment Diesel Exhaust Fluid Controller
#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 the Disassembly
D. Perform the “DEF Dosing System Verification Test” to pressurize and Assembly manual for the correct procedure.
the system.
E. Monitor the DEF Pressure (5) on the electronic service tool
screen during the test to see if the pressure stabilizes.
M0070030-01 183
(6) DEF header (7) DEF header filter (8) Sock filter
184 M0070030-01
Table 90
9. Replace the Filters and Flush the DEF Tank DEF Tank Filters Result: The DEF tank was flushed and the filters were
replaced.
B. Remove the DEF header from the DEF tank.
Refer to the Disassembly and Assembly manual for the correct
procedure.
C. Flush the DEF tank. Refer to Systems Operation, Testing

and Adjusting, “Diesel Exhaust Fluid Tank - Flush” for the cor-
rect procedure.
D. Replace the DEF header filter and DEF header sock filter.
Refer to Systems Operation, Testing and Adjusting, “Diesel Ex-
haust Fluid Tank - Flush” for the correct procedure.
10. Perform an “ Aftertreatment System Functional Test”” “Aftertreatment Sys- Result: The test is successful.
tem Functional Test”
B. Connect to the “Engine #1 Aftertreatment Controller” using Result: The test is not successful.
D. Perform the “Aftertreatment System Functional Test” .
11. Perform a “ DEF Dosing System Accuracy Test”” “DEF Dosing System Result: The amount of DEF collected is below 100 ml.
Accuracy Test” A failed DEF injector has been detected.
A. Connect to the electronic service tool.
Repair : Replace the DEF injector. Refer to the Disas-
B. Navigate to “Diagnostics Tests” . sembly and Assembly manual for the correct
procedure.
C. Perform a “DEF Dosing System Accuracy Test” using the
electronic service tool. Refer to Systems Operation, Testing Proceed to Test Step 12.
and Adjusting, “Aftertreatment SCR System Dosing Test” for
the correct procedure. Result: The amount of DEF collected is above 130 ml.
A failed DEF injector has been detected.
Repair : Replace the DEF injector. Refer to the Disas-

sembly and Assembly manual for the correct
procedure.
12. Perform an “ Aftertreatment System Functional Test”” “Aftertreatment Sys- Result: The test is successful.
tem Functional Test”
B. Connect to the “Engine #1 Aftertreatment Controller” using Result: The test is not successful. There are more
the electronic service tool. codes.
C. Navigate to “Diagnostics Tests” . Repair : Troubleshoot the additional codes. Refer to

the Troubleshooting manual for the correct procedure.
D. Perform the “Aftertreatment System Functional Test” .
M0070030-01 185
i06919127
DEF Tank Level Is Low
Diesel Exhaust Fluid (DEF) Tank Level

Inducement
Inducements are engine derates, vehicle speed
limits, or other actions intended to prompt the
operator to repair or maintain the emissions control
system.
Inducement strategies are control actions required by
EPA/ARB Tier 4 final and EU Stage IV regulations.
The control actions ensure prompt correction of
various failures in the engine NOx emissions control
system. Inducement strategies require actions to limit
engine performance. The strategies also define
required indications such as visual alarms including
lamps, messages, and audible alarms when the
control actions are imposed.
Table 91
Code Description
This code is a Level 3 inducement that becomes active when

Aftertreatment #1 Diesel Exhaust Flu- the DEF tank is empty. The engine is derated 100%, limited to
1761-1 E954 (3)
id Tank Level : Low - most severe (3) low idle or 1000 RPM, and may experience 5 minute rolling
shutdowns.
Aftertreatment #1 Diesel Exhaust Flu- This code is a Level 1 inducement that becomes active when
1761-17 E954 (1)
id Tank Level : Low - least severe (1) the DEF level is critically low.

This code is a Level 2 inducement that becomes active when
1761-18 E954 (2) id Tank Level : Low - moderate se-
the DEF level is critically low. Power loss may occur.
verity (2)
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 key to the OFF position before
adding DEF to the tank.
Table 92
Associated Diagnostic Codes
1235–9
5856–9
1235–14
5856–14
3516–12
3100–12
186 M0070030-01

steps are listed.
Table 93
1. Check for Associated Codes Codes Result: An associated code is not present.
A. Connect to electronic service tool. Proceed to Test Step 2.
B. Determine if there are associated codes present. Result: An associated code is present.
Repair: Troubleshoot the code.
2. Check the DEF Fluid Level Gauge Result: The gauge did not move by adding DEF to the
Position tank.
A. Turn the keyswitch to the ON position. Do not start the engine.
B. Check the current position of the DEF gauge.
Result: The gauge moved by adding DEF to the tank. Turn
C. Turn the keyswitch to the OFF position. the keyswitch to the OFF position for 2 minutes to allow the
DEF pump to purge, reset the code, and reset the Diesel
D. Clean dirt and debris from around the cap before removing the Exhaust Fluid Controller (DCU).
cap.
E. Add DEF to the DEF tank.
Only use DEF that meets ISO 22241 quality standards.
F. Turn the keyswitch to the ON position.
G. Check for a change in the gauge position.
M0070030-01 187
(1) DEF Tank Header connector (2) DEF Tank Header
188 M0070030-01
Table 94
3. Check the Electrical Connection at the DEF Tank Header Electrical Result: The electrical connectors are free of corrosion and
Connections are not loose.
A. Inspect the electrical connections to the DEF tank header. Re-
fer to Troubleshooting, Electrical Connectors - Inspect for further Proceed to Test Step 4.
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
Diesel Exhaust Fluid Controller (DCU).
4. Inspect the DEF Tank Header Proper Opera- Result: The float was not operating properly.
tion of the
A. Turn the keyswitch to the OFF position. Float Repair: Repair the float, if possible. If the float cannot be
repaired, replace the DEF tank header. Refer to the Disas-
B. Remove the tank header from the tank. Refer to the Disassem- sembly and Assembly manual for the correct procedure.
bly and Assembly manual for the correct procedure.
C. Inspect the DEF tank header for a stuck float.
Result: The float was operating properly.
Repair: Replace the DEF tank header. Refer to the Disas-

sembly and Assembly manual for the correct procedure.
i06661471
DEF Tank Temperature Is High
Table 95
Code Description
Aftertreatment 1 Diesel Exhaust Fluid Tank The code is logged when the DEF tank temperature ex-
3031-16 E960-2 ceeds 80° C (176° F).
Temperature : High - moderate severity (2)
Table 96
J1939 Code PDL Code

110-15 E361 (1)
110-16 E361 (2)
110-0 E361 (3)

steps are listed.
M0070030-01 189
Table 97
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.
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 not free of corrosion and/or
are loose.
B. Inspect for corrosion or loose wires.
Repair: Make the necessary repairs.
190 M0070030-01
Coolant line configuration may be different depending on the application.
(1) Coolant Supply Fitting (3) Coolant Return Fitting
(2) Coolant Diverter Valve (4) DEF Tank Header Connector
M0070030-01 191
Table 98
3. Check the Coolant Supply and Return Lines for Proper Correct Result: The lines are installed correctly.
Installation Installation
A. Inspect the coolant supply and return lines from the engine to
the Pump Electronic Tank Unit (PETU). Make sure that the cool- Result: The lines are not installed correctly.
ant is flowing in the correct direction.
Repair: Correctly install the lines. Refer to the Disassem-
B. Refer to Illustration 78 . bly and Assembly manual for the correct procedure. Pro-
ceed 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 “Diesel Exhaust Fluid Controller #1” using the elec- Repair: A failed coolant diverter valve has been detected.
tronic service tool. Replace the coolant diverter valve. Refer to the Disas-
sembly and Assembly manual for the correct procedure.
E. Start the engine. Allow the engine to warm up to operating
temperature. Proceed to Test Step 5.
F. Monitor the “DEF Tank Temperature” using the electronic serv-

ice tool.
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. Replace with DEF that meets ISO 22241 standards.
192 M0070030-01
i06661526
DEF Temperature Is Low
Table 99
Code Description

The DCU detects that the Diesel Exhaust Fluid (DEF) tank
3031-7 E1441 (2) Tank Temperature : Not Responding
temperature is not responding properly. The code is logged.
Properly

The DCU detects that the DEF tank temperature is lower than
3031-18 E1398 (2) Tank Temperature : Low - moderate
expected.
severity (2)

The DCU detects that the DEF tank temperature is not re-
3363-7 3126-7 Tank Heater : Not Responding
sponding properly during a heating cycle. The code is logged.
Properly

The DCU detects that the DEF pump temperature sensor is
5798-7 E1427 (1) Dosing Unit Heater Temperature : Not
not responding properly. The code is logged.
Responding Properly
The E1441 (2) or 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 E1427 (1) or 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 100
J1939 Code PDL Code

3363-5 3126-5
3363-6 3126-6
4354-5 3110-5
4354-6 3110-6
4355-5 3111-5
4355-6 3111-6
4356-5 3112-5
4356-6 3112-6
5491-5 3822-5
5491-6 3822-6

steps are listed.
M0070030-01 193
Table 101
Diagnostic Trou-
1. Check for Associated Diagnostic Trouble Codes ble Codes Result: An associated diagnostic trouble code is not
present.
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.
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 Pump Elec-
tronic Tank Unit (PETU) for leaks or damage that may cause Repair: Repair the leaks or damaged lines and refill the
restrictions. coolant system.
4. Check the Electrical Connection at the DEF Tank Header Electrical Result: The electrical connectors are free of corrosion
Connections and are not loose.
A. Inspect the electrical connections to the DEF tank header. Re-
fer to Troubleshooting, “Electrical Connectors - Inspect” for further Proceed to Test Step 5.
information.
Result: The electrical connections are not free of corro-
sion and/or are loose.
Look for corrosion or loose wires.
Repair: Make the necessary repairs to the connectors.
194 M0070030-01
(1) DEF tank header electrical connector (2) DEF tank header
Table 102
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 up to normal oper-
ating 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.
Refer to Troubleshooting, “Coolant Temperature Is Low”
D. Check the coolant temperature. for troubleshooting information.
The temperature should be greater than 50° C (122° F).
M0070030-01 195
(3) Coolant diverter valve (4) Coolant return to the engine water pump
inlet
196 M0070030-01
Table 103
6. Check the DEF Coolant Diverter Valve Operation “Aftertreatment Result: The “Aftertreatment Diesel Exhaust Fluid Tank
Diesel Exhaust Heater Test” was not successful.
A. Turn the keyswitch to the ON position. Fluid Tank Heat-
er Test” Repair: A failed coolant diverter valve has been de-
B. Start the engine. tected. Replace the coolant diverter valve. Refer to Dis-
assembly and Assembly for the correct procedure.
C. Connect to the electronic service tool.
D. Connect to the “Engine #1 Aftertreatment Controller”
Result: The “Aftertreatment Diesel Exhaust Fluid Tank
E. Perform the “Aftertreatment Diesel Exhaust Fluid Tank Heater Heater Test” was successful.
Test”
Result: A failed DEF pump temperature sensor has been
The DEF tank temperature must be within 5° C (9° F) of ambi- detected. Replace the DEF pump. Refer to Disassembly
ent air temperature prior to performing this service test. and Assembly for the correct procedure.
7. Check the DEF Tank Temperature Sensor Operation “Aftertreatment Result: The “Aftertreatment Diesel Exhaust Fluid Tank
Diesel Exhaust Heater Test” was successful. Return the unit to service.
A. Turn the keyswitch to the ON position. Fluid Tank Heat-
er Test” Result: The “Aftertreatment Diesel Exhaust Fluid Tank
B. Start the engine. Heater Test” was not successful.
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 #1 Aftertreatment Controller”
Refer to Disassembly and Assembly for the correct
E. Perform the “Aftertreatment Diesel Exhaust Fluid Tank Heater procedure.
Test”
Repeat the “Aftertreatment Diesel Exhaust Fluid Tank
The DEF tank temperature must be within 5° C (9° F) of ambi- Heater Test"”
ent air temperature prior to performing this service test.
If the “Aftertreatment Diesel Exhaust Fluid Tank Heater
Test” is successful, Return the unit to service.
i06919153
Desulfation Is Frequent

codes:

Features” for more information about service
features.
Table 104
Code Description
Aftertreatment 1 SCR Desulfation Too This code indicates that the engine is regenerating more fre-
6322-31 E1465 (1)
Frequent quently due to SCR problems.
M0070030-01 197
This code can log as a result of using fuel that does

not meet the Ultra Low Sulfur Diesel requirements.
An issue with urea deposits in the exhaust mixer or a
failed injector can also cause this code to log.
Table 105
Required Service Tools
Part Number Description
T400236 Kit - Test

steps are listed.
198 M0070030-01
Table 106
1. Check the Diesel Exhaust Fluid (DEF) Quality DEF Result : The DEF is not contaminated and the concen-
tration is not within the acceptable range.
A. Measure the DEF quality. Refer to Testing and Adjusting,
“Diesel Exhaust Fluid Quality - Test” for the correct procedure. Repair : Drain the DEF from the tank. Refill the tank with
DEF that meets ISO 22241 quality standards.
Result : The DEF is not contaminated and the concen-

tration is within the acceptable range.

2. Perform a “ DEF Dosing System Accuracy Test”” DEF Dosing Sys- Result : The quantity collected is within specifications
tem Accuracy Test
A. Perform a “DEF Dosing System Accuracy Test” using the Repair : Install the DEF injector.
electronic service tool. Refer to Systems Operation, Testing
and Adjusting, Aftertreatment SCR System Dosing Test for the Proceed to Test Step 4.
correct procedure.
Result : The quantity collected is below specification.
Result : The quantity collected is above specification. A

failed DEF injector has been detected.
Repair : Replace the DEF injector.
3. Check the DEF Pressure Line DEF Pressure Line Result : There are restrictions or leaks in the lines.
A. Turn the keyswitch to the OFF position for 2 minutes. The Repair : Remove the restrictions or replace the pressure
keyswitch must be OFF for 2 minutes to allow the DEF pump to line.
purge, reset the code, and reset the Dosing Control Unit (DCU).
B. Visually inspect the lines for leaks or damage.
Result : There are no restrictions or leaks in the lines.
C. Remove the DEF pressure line between the DEF pump and
the DEF injector. Proceed to Troubleshooting, “DEF Pressure is Low”.
D. Check for ice, urea deposits, or debris in the DEF pressure

line.
M0070030-01 199
200 M0070030-01
Table 107
4. Inspect the Exhaust Mixer for DEF Deposits Exhaust Mixer Result : There were no DEF deposits on the exhaust
mixer.
B. Remove the DPF outlet. Refer to the Disassembly and As-
sembly manual for the proper procedure. Result : There were DEF deposits on the exhaust mixer.
The exhaust mixer is damaged.
C. Inspect the exhaust mixer for DEF deposits.
Repair : Replace the exhaust mixer.
5. Determine the Quality of the Fuel Fuel Quality Result : The fuel being used does not meet the specifica-
tions for the engine.
A. Take a fuel sample from the fuel tank.
Refer to Testing and Adjusting, “Fuel Quality - Test” Repair : Contact the owner of the equipment. Inform the
owner that Ultra Low Sulfur Diesel must be used in order
for the engine to operate properly.
Drain the fuel tank and replace the fuel with fuel that
meets the specifications for the engine.
Perform a Manual DPF Regeneration using the electronic

service tool.
Return the unit to service after the regeneration has

completed.
6. Perform an “ Aftertreatment System Functional Test”” Aftertreatment Result: The test completed successfully.
System Functional
A. Start the engine. Test Return the unit to service.
B. Connect to the “Engine #1 Aftertreatment Control ECM” us-

C. Perform an “Aftertreatment System Functional Test.”

Diesel Particulate Filter The Engine Control Module (ECM) maintains an
Collects Excessive Soot estimate of the soot load in the Diesel Particulate
Filter (DPF). The estimate is based on the engine
operating conditions. If the ECM estimates that the
soot load is excessive, the ECM activates the
Use this procedure to troubleshoot excessive soot in applicable code.
the Diesel Particulate Filter (DPF). Also use this
procedure if one of the following event codes are Note: After the regeneration is complete and soot
active. Refer to Troubleshooting, “Event Codes” for loading is reduced to 0%, the active soot loading
information about event codes. For information on code will not change to a logged code or clear for 5
the engine monitoring system, refer to minutes.
Note: Certain systems will display multiple codes for
troubleshooting. These associated codes must be
used to troubleshoot the system effectively. Refer to
Troubleshooting, “General Information” for additional
information.
M0070030-01 201
Table 108

Codes PDL Code (code descriptions may vary) Comments
The engine has been running for 10 minutes after the E995 (3)
DPF Active Regeneration Inhibited Due to code was activated.
3714-31 E992 (3)
Temporary System Lockout The electronic service tool “Manual Diesel Particulate Filter Regen-
eration” must be initiated.
DPF Active Regeneration Inhibited Due to The estimated soot load is high. The engine may not operate prop-
3715-31 E991 (3)
Permanent System Lockout erly. Factory passwords are required to clear this code.
The estimated soot load is high. Engine operation is limited to 60

3719-0 E995 (3) High DPF #1 Soot Loading second intervals when the electronic service tool is not communi-
cating with the ECM.
The estimated soot load is high. The ECM shuts down the engine
when this code becomes active for the first time. The engine can
3719-16 E995 (2) High DPF #1 Soot Loading
be started and operated. Engine power is gradually derated as the
soot load increases.
Follow the troubleshooting procedure to determine the root cause of the problem.
Note: 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.
steps are listed.
202 M0070030-01
Table 109
1. Active Codes and Logged Codes Codes Result: A E991 (3) or 3715-31 code is present.
Result: One of the following codes are present:
B. Look for the following codes:
1. E995 (2) or 3719-16
1. E995 (2) or 3719-16
2. E995 (3) or 3719-0
2. E995 (3) or 3719-0
3. E992 (3) or 3714-31
3. E991 (3) or 3715-31
4. E992 (3) or 3714-31
2. E991 (3) or 3715-31 code DPF Result: An E991 (3) or 3715-31 code is present.
A. The E991 (3) or 3715-31 code indicates that the engine has con- Repair: Replace the DPF. Refer to the Disassembly and As-
tinued to run after repeated warnings and engine shutdowns. The sembly, “Diesel Particulate Filter - Remove and Install (Clean
DPF must be replaced. Refer to the Disassembly and Assembly, Emissions Module)” for the correct procedure.
“Diesel Particulate Filter - Remove and Install (Clean Emissions
Module)” for the correct procedure. After the DPF has been replaced, clear the E991 (3) or 3715-
31 code ( a factory password will be necessary) and proceed
to Test Step 3
Table 110
J1939 Code PDL Code

102-18 E1045 (2)
3474-31 E1026 (2)
3473-31 E1025 (2)
3703-31 E993 (2)
3609-15 E1156 (1)
3711-31 E593 (2)
3750-31 E1239 (1)
3474-14 E1026 (1)
3716-31 E1300 (2)
Table 111
3. Associated Codes Associated Result: An associated code is active or logged.

Codes
A. Establish communication between the electronic service tool Troubleshoot any codes that are present before continuing
and the Electronic Control Module (ECM). with this procedure.
B. Check the electronic service tool for any associated codes that Result: An associated code is not active or logged.
are listed in Table 110 .
M0070030-01 203
Table 112
4. Current Flow through the Heating Element Between 7 A and Result: The current flow is acceptable.
14 A for a 12 V
A. Start the engine. system Proceed to Test Step 5.
B. Use a clamp-on ammeter to check the current flow through Between 3.5 A Result: The current flow is not acceptable.
the heating element. and 7 A for a 24 V
system Repair: Refer to Troubleshooting, “ARD Nozzle - Test”
for the correct procedure.
5. ARD Combustion Air Test Combustion Air Result: The test results are unacceptable.
Test
A. Perform the “ARD Air System Service” . Repair: Refer to Troubleshooting, “ARD Combustion Air
- Test” for information on the test, if necessary. Make the
necessary repairs.
Result: The test results are acceptable.
6. Manual DPF Regeneration Manual DPF Result: The “Manual DPF Regeneration” was
Regeneration successful.
Do not use the cab switch for a stationary regeneration. The
service tests provide enhanced diagnostics that are necessary Return the engine to service.
for proper troubleshooting and repair.
Result: The “Manual DPF Regeneration” not was
A. Start a “Manual DPF Regeneration” in the electronic service successful.
tool.
Repair: Troubleshoot the diagnostic codes that are
present.
i06662141
Diesel Particulate Filter Has

Changed Regeneration
Interval
Note: Refer to this procedure if the interval between

DPF regenerations has changed.
steps are listed.
204 M0070030-01
Table 113
1. Check the Regeneration History Regeneration Result: The engine has logged 5000 hours since the last
History ash service regeneration
A. Connect the electronic service tool to the service tool
connector. Repair: Perform an ash service.
B. Open the “Information” tab. Contact your nearest Perkins Distributor if an ash service
is required.
C. Open the “History” tab.
Result: The engine has logged less than 5000 hours since
D. Open the “Aftertreatment Regeneration History” tab. the last ash service regeneration
E. Verify the following information: Proceed to Test Step 2.
1. If the regeneration intervals have changed
2. If the regeneration was manual or automatic
3. The soot level when the regenerations occurred.
M0070030-01 205
206 M0070030-01
Table 114
2. Inspect for Restrictions Restrictions Result: Restrictions were found.
A. Remove the DPF Differential Pressure sensor and lines group. Repair: Replace the affected components. Perform a
Manual DPF Regeneration using the electronic service
B. Closely inspect the sensors, elbows, lines, and manifold for re- tool to verify that the problem is resolved.
strictions. Restrictions could be caused by an accumulation of
moisture, ice, or soot. Result: Restrictions were not found.
“EGR System
3. Perform an “ EGR System Test”” Test” Result: The “EGR System Test” failed.
A. Start the engine. Repair: Proceed to Troubleshooting, “NOx Reduction Sys-

tem (NRS) - Test” to troubleshoot the EGR system.
B. Perform an “EGR System Test” using the electronic service
tool.
i06662199

High Ash Load

codes:
Table 115

The diesel particulate filter has not been cleaned according to
3720-15 E997 (1) High DPF #1 Ash Loading (1)
the maintenance interval schedule.
The diesel particulate filter has not been cleaned according to
3720-16 E997 (2) High DPF #1 Ash Loading (2) the maintenance interval schedule. Regenerations are occurring
more frequently.

Table 116
1. Determine the active code, Active Code Result: A 3720–15 (E997 (1)) code is active.
Result: A 3720–16(E997 (2)) is active.
B. Determine the code.
(continued)
M0070030-01 207
(Table 116, contd)
2. Determine the Most Recent Cleaning of the DPF. DPF Result: The diesel particulate filter has not been cleaned ac-
Cleaning cording to the maintenance interval schedule. The mainte-
A. Determine the last time the DPF was cleaned. nance interval schedule is listed in the Operations and
Maintenance Manual.
Result: The diesel particulate filter was cleaned according to

the maintenance interval schedule. The diesel particulate fil-
ter was cleaned within the last 500 hours but the engine ash
model was not reset. Reset the engine ash model. Refer to
Troubleshooting, “Service Tool Features” for information on
resetting the ash model.
Result: The DPF was cleaned according to the Maintenance

Manual and more than 500 hours of engine operation has oc-
curred. Also, the engine ash model was not reset.
3. Clean the DPF DPF Result: The DPF was cleaned.
A. Clean the DPF. Refer to Systems Operation and Testing and Verify that the problem is resolved.
Adjusting, “Diesel Particulate Filter - Clean” for the correct
procedure.
After an ash service regeneration, there will be a delay in soot ac-

cumulation shown on the gauge.
i06662334

High Inlet Pressure
Use this procedure if the following event code is

active. Refer to Troubleshooting, “Event Codes” for
information about event codes.
Table 117

(code descriptions may vary)
3609-15 E1156 (1) High DPF #1 Intake Pressure The code is logged.
208 M0070030-01
Table 118
J1939 Code PDL Code

3719-16 E995 (2)
3719-0 E995 (3)
3720-15 E997 (1)
3720-16 E997 (2)
Table 119
1. Check for Associated Diagnostic Trouble Codes Associated Diag- Result: An associated diagnostic trouble code is not
nostic Codes present.
and the engine Electronic Control Module (ECM). Proceed to Test Step 2.
Result: An associated diagnostic trouble code is

B. Determine if any of the codes in Table 118 are present. present.
Repair: Refer to Troubleshooting, “Event Codes” to trou-

bleshoot the associated diagnostic code.
Result: The diesel particulate filter was cleaned within

2. Ash Service Maintenance Cleaning Interval the last 5000 hours.
A. Determine the most recent cleaning of the Diesel Particulate Proceed to Test Step 3.
Filter (DPF).
Result: The diesel particulate filter was not cleaned
within the last 5000 hours.
(continued)
M0070030-01 209
(Table 119, contd)

Result: There is oil, fuel, or coolant on the DPF and/or
3. Check for Contamination Contamination the DOC.
A. Reset all active codes and clear all logged codes by using the Repair: Perform the following procedure:
1. Clean the DPF.
B. Remove the DPF.
2. Cleaning the DPF is not an ash service cleaning. Do
C. Check for contamination on the face of the DPF and the Diesel not reset the engine ash model. The ash cannot be re-
Oxidation Catalyst (DOC). moved from the DPF if soot is present.
3. Reconnect the DOC and the DPF.
4. Start the engine. Run the engine at 1400 RPM with no

load. Run the engine for at least 15 minutes or run the
engine until there is no more white smoke.
If the E1156 (1) or 3609-15 diagnostic code remains ac-

tive, replace the DPF. Return the unit to service.
If the DOC needs to be replaced. Perform a DOC reset.
Result: There are no active diagnostic codes.

4. Perform an Ash Service Active Codes
A. Reset all active codes and clear all logged codes by using the
electronic service tool. Result: The E1156 (1) or 3609-15 diagnostic code is
active.
B. Clean the DPF. Refer to Systems Operation and Testing and
Adjusting, “Diesel Particulate Filter - Clean” for the correct Repair: Replace the DPF. Reset all active codes and
procedure. clear all logged codes by cycling the keyswitch to the
OFF position. Perform an “ARD Ignition Test” to verify
C. Perform an “ARD Ignition Test” in the electronic service tool. that the problem is resolved.
Check for the E1156 (1) or 3609-15 diagnostic code.
i06666633

Low Inlet Pressure
The probable cause of low inlet pressure of the

Diesel Particulate Filter (DPF) is an exhaust leak.

210 M0070030-01
Table 120
Code Description
J1939 Codes PDL Code Comments
3609-17 E1154 (1) Low DPF #1 Intake Pressure The code is logged.
3609-18 E1154 (2) Low DPF #1 Intake Pressure The code is logged.

steps are listed.
Table 121
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 Aftertreatment Regeneration Device (ARD) as- service.
sembly inlet.
Result: The exhaust system does not have leaks.
B. Check the exhaust system for loose connections or open
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.
i06666688
Diesel Particulate Filter

Temperature Is High
The A5:E2 Aftertreatment Controller monitors the

temperature at the intake of the Diesel Particulate
Filter (DPF). The controller activates the applicable
code when the conditions are met.

steps are listed.
M0070030-01 211
Table 122

Code PDL Code
The temperature at the intake of the DPF exceeded a predeter-
Aftertreatment 1 Diesel Particulate Filter Intake
3242-15 E1008 (1) mined value.
Gas Temperature High (1)
Active regeneration is immediately disabled. The code is logged.
The temperature at the intake of the DPF exceeded a predeter-

Aftertreatment 1 Diesel Particulate Filter Intake
3242-16 E1008 (2) mined value.
Gas Temperature High (2)
Active regeneration is immediately disabled. The code is logged.
Table 123
J1939 Code PDL Code

3480-15 E1050 (1)
3480-16 E1050 (2)
4077-16 E1051 (2)
Table 124
1. Check for Associated Diagnostic Trouble Codes Associated Codes Result: An associated diagnostic trouble code is not ac-
tive or logged.
A. Establish communication between the electronic
service tool and the ECM. Refer to Troubleshooting, Proceed to Test Step 2.
Result: An associated code is active or logged.
B. Check for any active associated diagnostic codes Repair: Troubleshoot the associated codes before con-
listed in Table 123 . tinuing with this procedure.
Refer to Troubleshooting, “Event Codes” to troubleshoot

the associated diagnostic code.
2. Check for Boost Leaks Service Test Result: The “ARD Air System Service Test” failed.
A. Establish communication between the electronic There is a problem with the ARD combustion air.
service tool and the ECM. Refer to Troubleshooting,
“Electronic Service Tools”, if necessary. Repair: Refer to Troubleshooting, “ARD Combustion Air -
Test”.
B. Perform an “ARD Air System Service Test” .
Result: The “ARD Air System Service Test” was
successful.
(continued)
212 M0070030-01
(Table 124, contd)

3. Check for High Exhaust Temperatures High Exhaust Result: The engine is experiencing high exhaust temper-
Temperatures atures. Repair the cause of the high exhaust temperature.
A. Several factors can cause a calculated high exhaust
temperature. Refer to Troubleshooting, Exhaust Tem- Result: The engine is not experiencing high exhaust
perature Is High for further information on calculated temperatures.
high exhaust temperatures
4. Perform a Manual Cylinder Cutout Test. Faulty Injector Result: A faulty injector is found.
A. Remove the inlet section (DOC) from the DPF. Repair: Replace any injectors that cause the engine to
smoke and run rough when the cylinder is not cut out.
B. Use the electronic service tool to set the value of the Clean inside the inlet section of the DPF.
“ARD Manual Disable Status” configuration parameter Assemble the DPF. The engine must be run with no load
to “Disabled” to disable the ARD. at 1400 rpm for at least 15 minutes. If the white smoke
continues after 15 minutes, the engine must continue to
C. Perform a manual cylinder cutout test. Manually cut run until there is no white smoke.
out each cylinder whilst the exhaust is monitored. As
each cylinder is cut out, look for a decrease in white Set the value of the “ARD Manual Disable Status” configu-
smoke. ration parameter to “Not Disabled” to enable the ARD.
Result: A faulty injector is not found.
5. Inspect the DPF Oil, Excessive Soot or Result: Oil is found.

Plugging
A. Remove the inlet section (DOC) from the DPF. Repair: Perform the following procedure:
1. Inspect the outlet of the turbocharger. Clean the oil from
B. Inspect inside the inlet section and the front face of inside the inlet section of the DPF.
the DPF. Look for oil and for excessive soot. 2. Assemble the DPF. The engine must be run with no
load at 1400 rpm for at least 15 minutes. If the white
C. Inspect the inlet to the Diesel Oxidation Catalyst smoke continues after 15 minutes, the engine must con-
(DOC). Inspect the inlet of the catalyst and check the tinue to run until there is no white smoke.
catalyst for plugging. Proceed to Test Step 6.
A small amount of soot is a normal condition. Contact Result: Oil is not found.
your Perkins distributor if you suspect that the amount
of soot is excessive. Continue with this procedure after Proceed to Test Step 6.
you have received guidance from the Perkins
distributor.
(continued)
M0070030-01 213
(Table 124, contd)

6. Perform a “ Manual DPF Regeneration”” Test Result: The “Manual Diesel Particulate Filter Regenera-
tion” was successful.
ice tool. The electronic service tool enhances the diag- Return the engine to service.
A. Reset all active codes and clear all logged codes. Result: The “Manual Diesel Particulate Filter Regenera-
tion” was not successful.
B. Start a “Manual DPF Regeneration” .
Repair: Troubleshoot any diagnostic codes that are
present, if no codes are present, Proceed to Test Step 7.
7. Replace the ARD Combustion Head Test Result: The ARD Ignition Test was successful.
A. Replace the ARD combustion head. Return the engine to service.
B. Select the ARD Ignition Test tab. The ARD Ignition

Test cannot be performed if the DPF soot loading is
above 80%. When the DPF soot loading is above 80%,
the Manual DPF Regeneration must be performed us-
C. Perform an "ARD Ignition test". to verify proper oper-

ation of the Regeneration system.
i06666753
Diesel Particulate Filter

Temperature Is Low
The A5:E2 Aftertreatment Controller monitors the

temperature at the intake of the Diesel Particulate
Filter (DPF). The A5:E2 Aftertreatment Controller
activates the applicable code when the conditions are
met.

Table 125

Code PDL Code
The Aftertreatment Regeneration Device (ARD) has ignited and
the A5:E2 Aftertreatment Controller has detected Low DPF inlet
temperature.
Active regeneration is immediately disabled. Engine power is de-

rated. The code is logged. The code remains active until electrical
3242-18 E1014 (2) Low DPF #1 Intake Temperature
power to the A5:E2 Aftertreatment Controller is cycled. The follow-
ing conditions can cause this code:
The exhaust piping between the outlet of the ARD and the intake
of the DPF is disconnected and/or the DPF Inlet Temperature sen-
sor has failed.
214 M0070030-01
(1) Exhaust piping (2) Clamps

steps are listed.
Table 126
1. Inspect the Exhaust Piping Damaged or Result: The piping is not damaged or missing.
Missing
A. Carefully Inspect the exhaust piping between the outlet of the Piping Proceed to Test Step 2.
ARD and the intake of the DPF. Look for the following problems:
Result: The piping is damaged or missing.
1. Missing piping, cracked piping, or disconnected piping
Repair: Make the necessary repairs. Proceed to Test Step
2. Broken clamps or missing clamps 2.
M0070030-01 215
(3) DPF inlet temperature sensor and wiring
Table 127
2. Inspect the DPF Inlet Temperature Sensor and Wiring Damaged Result: The wiring and sensor are not damaged.
Wiring or
A. Carefully inspect the DPF Inlet temperature sensor wiring for Sensor Proceed to Test Step 3.
damage.
Result: The wiring and sensor are damaged.
B. Carefully inspect the DPF Inlet temperature sensor for damage.
Repair: Make the necessary repairs. Proceed to Test Step
3.
3. Perform an “ ARD Ignition Test”” Test Result: The “ARD Ignition Test” was successful.
A. Connect to the electronic service tool. Return the engine to service.
B. Select the Diagnostics tab. Result: The “ARD Ignition Test” was not successful.
C. Select the Diagnostic Tests tab. Repair: Replace the DPF inlet temperature sensor. Re-
peat the “ARD Ignition Test” .
D. Select the “ARD Ignition Test” tab.
If the “ARD Ignition Test” was successful, return the engine
The “ARD Ignition Test” cannot be performed if the DPF soot load- to service.
“Manual DPF Regeneration” must be performed using the elec- If the “ARD Ignition Test” was not successful, troubleshoot
tronic service tool. the generated codes.
216 M0070030-01
i06666956
Engine Cranks but Does Not

Start
Note: If the symptom is intermittent and the symptom

cannot be repeated, refer to Troubleshooting, “Power
Is Intermittently Low or Power Cutout Is Intermittent”.
If the symptom is consistent and the symptom can be
repeated, continue with this procedure.
Check the electronic service tool for any associated
codes that are listed in Table 128 . Troubleshoot any
Table 128
J1939 Code PDL Code

5584–15 E390 (1)
5584–16 E390 (2)
1347–5 1779–5
1347–6 1779–6
1348–5 1780–5
1348–6 1780–6
5580–18 E198 (2)
Note: If the engine will not start and the electronic

service tool will not communicate with the ECM, the
problem is most likely with the electrical power supply
to the ECM. Refer to Troubleshooting, “Electrical
Power Supply - Test”.
M0070030-01 217
Table 129
1. Inspection of the Fuel Supply Fuel Level Result : The fuel level is OK.
A. Visually check the fuel level in the fuel tank. Do not rely Proceed to Test Step 2.
on the fuel gauge only.
Result : The fuel level is not OK.
B. Ensure that the fuel supply valve (if equipped) is in the
full OPEN position. Repair : Fill the tank.
STOP
2. Check the Engine Shutdown Switches (if applicable) Engine Shutoff Result : The switches are in the OFF position.
Switches
A. The engine shutdown switches must be in the OFF Proceed to Test Step 3.
position.
Result : The switches are not in the OFF position.
B. Use the electronic service tool to verify the status of the
engine shutdown switches. When a shutdown occurs, the Repair : Turn the switches to the OFF position.
keyswitch must be turned to the OFF position for at least 15
seconds before restarting the engine. STOP
3. Check the Engine Starting Aids (if applicable) Starting Aids Result : The starting aid is operating correctly.
A. If cold ambient conditions exist, check the operation of Proceed to Test Step 4.
the starting aids. Verify that the starting aid is operating
correctly. Result: The starting aid is not operating correctly.
Repair : Refer to the appropriate circuit test to troubleshoot

the starting aid.
4. Restrictions in the Air Inlet and Exhaust System Air and Exhaust Result : There are no system restrictions.
System
A. Check for an air filter restriction indicator. Restrictions Proceed to Test Step 5.
B. Check the air inlet and exhaust system for restrictions Result : There are system restrictions.
and/or leaks.
Refer to Testing and Adjusting, “Air Inlet and Exhaust System
- Inspect” for more information on air system restrictions.
Repair : Replace plugged air filters. Refer to the Operation

and Maintenance Manual for the correct procedure.
5. Check for Activation of the Theft Deterrent System (if Theft Deterrent Result : The theft deterrent system is not active.
applicable) System
A. Verify that the theft deterrent system is not active.
Result : The theft deterrent system is active.
Repair : Turn the theft deterrent system OFF.
(continued)
218 M0070030-01
(Table 129, contd)

6. Check the Coolant Temperature Sensor for Proper Coolant Tempera- Result : The sensor is operating properly.
Operation ture Sensor
A. The coolant temperature sensor must provide a correct
signal in order for cold mode operation to operate correctly. Result : The sensor is not operating properly.
Refer to "Cold Mode Operation" within the Systems Oper-
ation, “General Information”. Repair : Refer to Troubleshooting, “Sensor Signal (Analog,
Passive) - Test” for troubleshooting information.
B. Verify that the coolant temperature reading in the elec-
tronic service tool is reasonable for the conditions that are
present.
7. Check the Engine/Speed Signal for Proper Operation Timing Signal Result : The timing sensor is operating properly.
A. Crank the engine and observe the engine speed on the Proceed to Test Step 8.
electronic service tool status screen. Refer to Troubleshoot-
ing, “Speed/Timing - Test” for additional information. Result : The timing sensor is not operating properly.
Upon initial cranking, the status for engine speed may indi- Repair : Refer to Troubleshooting, “Speed/Timing - Test” for
cate that the engine speed signal is abnormal. This mes- troubleshooting information.
sage will be replaced with an engine speed once the ECM
is able to calculate a speed from the signal.
8. Inspect the Low-Pressure Fuel System Low-Pressure Fuel Result : The low-pressure fuel system is operating properly.
System
A. Inspect the fuel system. Refer to Systems Operation, Proceed to Test Step 9.
Testing and Adjusting, “Fuel System” for additional
information. Result : The low-pressure fuel system is not operating
properly.
B. Cold weather adversely affects the characteristics of the
fuel. Refer to the Operation and Maintenance Manual for in- Repair : Make the necessary repairs. Return the engine to
formation on improving the characteristics of the fuel during service.
cold-weather operation.
C. Check fuel quality. Refer to Systems Operation, Testing

and Adjusting, “Fuel System” for the proper procedure.
Check the fuel tank for debris or foreign objects which may
block the fuel supply.
D. Check the filtered fuel pressure whilst the engine is

being cranked. Refer to Systems Operation, Testing and
Adjusting, “Fuel System” for the test procedure and for the
correct pressure values.
If the fuel pressure is low, replace the fuel filters. Clean the
primary filter/water separator of debris. Refer to the Opera-
tion and Maintenance Manual for details.
E. Check for the proper operation of the fuel transfer pump.

Refer to Systems Operation, Testing and Adjusting, “Fuel
System” for test information.
9. Inspect the High-Pressure Fuel System High-pressure Fuel Result : The high-pressure fuel system is not operating
System properly.
A. Perform the Testing and Adjusting, “Injector Bypass Fuel
Flow - Test” to test the high-pressure fuel system. Repair : Make the necessary repairs. Return the engine to
service.
M0070030-01 219
i06251919
Engine Does Not Crank
Use this procedure to troubleshoot an engine that will

not crank.
Table 130
1. Inspection of the Batteries and Battery Cables Batteries are OK 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. STOP.
B. Inspect the batteries.
C. Test 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. If equipped, check any switches and/or circuit breakers that are OK Proceed to Test Step 3.
may interfere with the engine cranking. Refer to the applications
electrical schematic for additional information. Result The switches and/or circuit breakers are not OK.
3. Starting Motor Solenoid and Starting Circuit Starting motor Result The starting motor solenoid and circuit are OK.
solenoid and cir-
A. Test the operation of the starting motor circuit. Refer to Sys- cuit are OK. 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.
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 are OK 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.
Make the necessary repairs. STOP.
(continued)
220 M0070030-01
(Table 130, contd)

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

may lock up the engine:
1. Hydraulic pump that is driven from the rear gear group

2. Air compressor
3. Engine oil pump
4. Other components that are driven by the engine
6. Hydraulic Cylinder Lock Hydraulic cylin- Result The engine has hydraulic cylinder lock.
der lock
A. If an injector has been replaced, evacuate any fluids from the Repair: Make the necessary repairs. STOP.
cylinder and attempt to start the engine. Fuel will flow from the
cylinder head into the cylinders when a unit injector is removed.
B. If the engine will not start, check for fluid in the cylinders (hy-
draulic cylinder lock) by removing the individual unit injectors.
Check for damaged seals. Determine the type of fluid that
locked up the cylinder.
C. If there was a coolant leak, determine the cause of the leak.

Check the exhaust (NRS) cooler for leaks. Refer to 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:
1. Seizure
2. Broken components
3. Bent components
Complete the procedure in the order in which the • Low oil pressure
steps are listed.
• Leaks in the air system
i06251981
• Inspect the fuel filters for contamination.
Engine Has Early Wear
Recommended Actions
Probable Causes
• Incorrect maintenance intervals and/or incorrect
oil
• Contaminated engine oil
M0070030-01 221
Table 131
1. Incorrect Maintenance Intervals and/or Incorrect Oil Maintenance Result: The engine oil was changed at the interval that is
intervals recommended by the engines Operation and Mainte-
A. Use engine oil that is recommended and change the engine oil nance Manual.
at the interval that is recommended by the engines Operation and
Maintenance Manual. Proceed to Test Step 2.
Result: The engine oil was not changed at the interval

that is recommended by the engines Operation and Main-
tenance Manual.
Repair: Use at least the minimum recommended grade

of oil. refer to the Operation and Maintenance Manual.
Change the engine oil at the interval that is recom-

mended. Repair or replace any damaged parts.
2. Contaminated Engine Oil Contamination Result: The oil is contaminated.
A. Check the engine oil for contamination. Repair: Determine the reason for any contamination of
the engine oil and make the necessary repairs. Drain the
B. Check the oil filter bypass valve. crankcase and refill the crankcase with clean engine oil.
Install new engine oil filters. Refer to the engines Opera-
If the oil filter bypass valve is open, the oil will not be filtered. 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 Result: The oil is not contaminated.
bypass valve is operating correctly. Refer to the Disassembly and
Assembly manual. Proceed to Test Step 3.
3. Low Oil Pressure Restriction Result: The inlet tube has a restriction.
A. Engine oil that is contaminated with another liquid can cause Repair: Clear the obstruction. Verify the repair.
low engine oil pressure. High engine oil level can be an indication
of contamination. Obtain an analysis of the engine oil. Result: The inlet tube does not have a restriction.
B. The inlet screen of the suction tube for the engine oil pump can Proceed to Test Step 4.
have a restriction. This restriction will cause cavitation and a loss
of engine oil pressure. Check the inlet screen on the suction tube
and remove any material that may be restricting engine oil flow.
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 indi-
cator for the engine oil pressure may indicate sufficient pressure,
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.
(continued)
222 M0070030-01
(Table 131, contd)

4. Leaks in Air System Air leak Result: There are no air leaks.
A. A leak in the air intake system may allow unfiltered air into the Proceed to Test Step 5.
engine. Inspect the air intake system for streaks which may indi-
cate a leakage of unfiltered air. Inspect all of the gaskets and the Result: There are air leaks.
connections.
Repair: Repair any leaks.
5. Inspect the Fuel Filters for Contamination Fuel filters Result: The fuel has contamination.
A. Remove the fuel filters. Inspect the fuel filters for contamina- Repair: Determine the cause of any contamination and
tion. Contaminants in the fuel such as hydrogen sulfide and sulfur make the necessary repairs.
can lead to the formation of acids in the crankcase. Obtain a fuel
analysis. Install new fuel filters. Refer to the Operation and Mainte-
nance Manual.

steps are listed.
i06668262
Engine Has Mechanical Noise

(Knock)
Probable Causes
• Electrical connections
• Fuel injection
• Fuel quality
• Proper lubrication
• Isolate the source of the noise.

• Gear train and lower end components

• Crankshaft
Recommended Actions
M0070030-01 223
Table 132
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.
Result: There are no active codes.
B. Check for active diagnostic codes.
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.
3. Fuel Injection Diagnostic Result: The test was successful.

Test
A. Perform the “Injector Solenoid Test” on the electronic service Proceed to Test Step 4.
tool to determine if all the injector solenoids are being energized
by the ECM. Result: The test was not successful.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests” Repair: Diagnose the problem and then repair the problem.
service tool. Verify that the repair eliminated the problem.
4. Fuel Quality Fuel Result: The fuel quality is OK.
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 System Quality Test” for the proper procedure. Repair: Replace the fuel. Verify that the repair eliminated
the problem.
(continued)
224 M0070030-01
(Table 132, contd)

5. Proper Lubrication Lubrication Result: The oil passages are not blocked and the engine
A. Check for proper lubrication of the valve components. Check
for sufficient lubrication between the injector tappets and the rock- Proceed to Test Step 6.
er arms.
C. Inspect the engine oil filters for ferrous material.
D. Check the engine oil for contamination.
6. Isolate the Source of the Noise Engine Result An engine accessory is the source of the noise.
accessory
A. If the source of the noise is the engine accessory, remove the Repair: Repair the engine accessory and/or replace the en-
suspect engine accessory. Inspect the suspect engine accessory. gine accessory, if necessary.
Result An engine accessory is not the source of the noise.
Excessive”.
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 problem.
1. Camshaft
2. Valve rotocoil
3. Valve springs
5. Rocker shaft
6. Bridges
7. Pushrods
8. Injectors
(continued)
M0070030-01 225
(Table 132, contd)

damaged.
Result: The gear train or lower end components are not

damaged.
9. 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 problem.
B. Inspect the connecting rod bearings and the bearing surfaces
on the crankshaft. Make sure that the bearings are in the correct
position.
C. Check the counterweight bolts.
i06668280
Engine Misfires, Runs Rough

or Is Unstable

Probable Causes
• Low quality fuel

• Fuel injectors
• Lack of lubrication
• Gear train and components of the lower end
Recommended Actions
226 M0070030-01
Table 133
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.
Troubleshoot any active codes before continuing with this
procedure.
2. Fuel Quality Fuel Result: The fuel quality is OK.
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 proper procedure. Repair: Replace the fuel. Verify that the repair eliminated
the problem.
3. Fuel Injectors Diagnostic Result: The test was successful.

Test
If service has been performed on the engine fuel system recently, Proceed to Test Step 4.
verify that the injector trim files are correct. Use the electronic serv-
ice tool to check that the injector trim files are correct for the injec- Result: The test was not successful.
tors that are installed on the engine.
Repair: Diagnose the problem and then repair the problem.
A. Perform the “Injector Solenoid Test” on the electronic service
tool to determine if all the injector solenoids are being energized Reset all active codes and clear all logged codes.
by the ECM.
Verify that the repair eliminated the problem.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests”

service tool.
4. Proper Lubrication Lubrication Result: The oil passages are not blocked and the engine
A. Check for proper lubrication of the valve components. Check for
sufficient lubrication between the injector tappets and the rocker Proceed to Test Step 5.
arms.
C. Inspect the engine oil filters for ferrous material.
D. Check the engine oil for contamination.
(continued)
M0070030-01 227
(Table 133, contd)

Excessive”.
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 problem.
1. Camshaft
2. Valve rotocoil
3. Valve springs
5. Rocker shaft
6. Bridges
7. Pushrods
8. Injectors
damaged.

steps are listed.
i06668289
Engine Overcrank Occurrence

Table 134

The code is logged.
1664-31 E225 (3) Engine Automatic Start Failed
The fuel is shut off. Engine cranking is prevented.
228 M0070030-01
Probable Causes
• Diagnostic Codes
• Starting Aids (if applicable)
• Load
• Fuel Supply
• Battery
• Charging Circuit
• Starter
Recommended Actions
Table 135
1. Check for Associated Diagnostic Trouble Codes Associated Result: An associated diagnostic trouble code is not active
Codes or logged.
and the ECM. Refer to Troubleshooting, “Electronic Service Proceed to Test Step 2.
Tools”, if necessary.
B. Use the electronic service tool to check for active associated Repair: Troubleshoot the associated codes before continu-
diagnostic codes. ing with this procedure.
Refer to Troubleshooting, “Diagnostic Trouble Codes” or

Troubleshooting, Event Codes to troubleshoot the associated
diagnostic code.
2. Starting Aids (if applicable) Starting Aids Result: The starting aid is operating correctly.
A. If cold ambient conditions exist, check the operation of the Proceed to Test Step 3.
starting aids.
Result: The starting aid is not operating correctly.
B. Verify that the starting aid is operating correctly.
Repair: Refer to the appropriate circuit test to troubleshoot
the starting aid.
3. Excessive Loads Excessive Result: The 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.
(continued)
M0070030-01 229
(Table 135, contd)

4. Inspection of the Fuel Supply Fuel Level Result: The fuel level is OK.
A. Visually check the fuel level in the fuel tank. Do not rely on Proceed to Test Step 5.
the fuel gauge only.
Result: The fuel level is not OK.
B. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position. Repair: Fill the tank.
C. Check the fuel quality. If necessary, add fuel. If the engine has been run out of fuel,
purge the air from the fuel system.
Make sure that the fuel meets the requirements of Operation
and Maintenance Manual.
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 for in-
formation on improving the characteristics of the fuel during
5. Worn Battery Battery Result: The battery will no longer hold a charge.
A. Verify that the battery is no longer able to hold a charge. Refer Repair: Replace the battery. Refer to Disassembly and As-
to Systems Operation, Testing and Adjusting for the correct sembly for the correct procedure.
procedure.
Result: The battery will hold a charge.
6. 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 7.
charging circuit.
Result: The battery circuit is not OK.
B. Verify that 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. Refer to Systems Operation, Testing and Adjusting for
Alternator
7. Alternator Result: The condition of the alternator is OK.
A. Inspect the condition of the alternator. Refer to Troubleshoot- Proceed to Test Step 8.
ing, “Alternator Problem” for the correct procedure.
Result: The condition of the alternator is not OK.
Repair: Replace or repair the alternator.
(continued)
230 M0070030-01
(Table 135, contd)

Starter
8. Starter Engagement Engagement Result: The relay for the starting motor indicates that the en-
gine should crank but no cranking occurs.
A. Attempt to start the engine whilst 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.
Crank Cycle
9. Crank Cycle Result: The engine cannot be cranked for enough time.
A maximum of one crank cycle per overcrank is recommended. Repair: Use the electronic service tool to check the “Cycle
Crank Time” and the “Overcrank Time” parameters. Remem-
A. Make sure that the engine can be cranked for enough time. ber that the purge cycle is part of the total crank cycle. Repro-
gram the parameters, if necessary.
i06668332
Engine Overspeeds
Use this procedure to troubleshoot an engine

overspeed or use this procedure if the following event
code is active. Refer to Troubleshooting, “Event
Codes” for information about event codes. For
information on the engine monitoring system, refer to
Table 136
Code Description
(code descriptions may
J1939 Code PDL Code vary) Comments
190-0 E362 (3) Engine Overspeed The code requires factory passwords to be cleared.
190-15 E362 (1) Engine Overspeed The code is logged.
Probable Causes
• Proceeding down steep grades (if applicable)
• Proper operation of the turbocharger

• Intake air
• Starting aids that are not operating properly
Recommended Actions
M0070030-01 231
Table 137
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 Repair: Control the engine speed during steep grades.
necessary.
Result: Steep grades are not the cause of the overspeed.
A. The operator needs to understand the proper operation of
the machine when using the engine brakes. Proceed to Test Step 2.
Not all applications have engine brakes.
2. Proper Operation of the Turbocharger Turbocharger Result: The turbocharger is leaking oil into the inlet.
A. Check for proper operation of the turbocharger. Repair: Repair or replace the turbocharger.
B. Check for any oil that may be leaking into the air inlet. Result: The turbocharger is not leaking oil into the inlet.
3. 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 proper operation of starting aids (if equipped).
i06668362
Engine Shutdown Occurrence
The “Delayed Engine Shutdown” (DES) feature

allows the engine to run after the keyswitch has been
turned to the OFF position. “Delayed Engine
Shutdown” (DES) allows the engine and exhaust
temperatures to cool to an acceptable level prior to
shutting down the engine. If the delayed engine
shutdown is aborted, potential damage to the engine
and/or aftertreatment system can occur. These fault
codes may indicate that the engine was shut down
when the exhaust temperatures were still above the
acceptable threshold.
event codes.
232 M0070030-01
Table 138
Code Description
J1939 Codes PDL Code (code descriptions may vary) Comments
- E265 (1) The inputs from the user-defined shutdown
switch to the Electronic Control Module
User Defined Shutdown
(ECM) have changed states. The engine will
shut down. The code is logged.


E268 (3) Unexpected Engine Shutdown The engine has stopped unexpectedly. The
5272–31 engine speed is 0 whilst the ECM is request-
E369 (3) Engine Stall Condition ing engine speed.
6588-31 E1466 (1) The Engine was stopped before cooling of the
Operator Shutdown With High Exhaust
exhaust system could complete. Allow De-
Temperature
layed Engine Shutdown to complete.
Probable Causes for a E1466 or

6588-31 Code
• An operator turning the keyswitch to the fourth
position or forcing a shutdown prior to DES
completing
• DES may not be enabled
• Fuel ran out prior to DES completion

• Mechanical failure causing the engine to stop prior
to DES completion
Probable Causes for a E265 Code

• Activated shutdown switch
• Circuit for the shutdown switch
Probable Causes for a E268, E369,

or 5272-31 Code
• Operator caused the engine to stall
• Fuel supply
• Mechanical Failure
Table 139
J1939 Code PDL Code
(continued)
M0070030-01 233
(Table 139, contd)

4215-31 E678 (1)
4215-31 E678 (2)
4215-31 E678 (3)
- E1217 (3)

steps are listed.
Table 140
1. Determine the Code Active Codes Result: An associated code is active.
A. Establish communication between the electronic service tool Repair: Refer to Troubleshooting, “Event Codes” to trouble-
and the ECM. Refer to Troubleshooting, “Electronic Service Tools”, shoot the associated diagnostic code.
if necessary. Troubleshoot the associated code before continuing
with this procedure.
B. Determine the event code. Result: An E265 code is active or logged.
Result: An E268 (3), E369 (3), or 5272-31 code is active or

logged.
Result: An E1466 or 6588-31 code is active or logged.
2. Delayed Engine Shutdown Delayed En- Result: “Delayed Engine Shutdown” is enabled.
gine
A. Check if “Delayed Engine Shutdown” is enabled. Shutdown Proceed to Test Step 3.
B. Connect to the electronic service tool and navigate to the “Con- Result: “Delayed Engine Shutdown” is not enabled.
figuration” tab in the engine ECM. Select the “Delayed Engine
Shutdown” tab and check the status of the parameter. Repair: Enable “Delayed Engine Shutdown” .
Verify that enabling “Delayed Engine Shutdown” eliminated

the problem.
3. Proper Engine Operation Operator Result: The operator is operating the engine correctly.
A. Interview the operator and determine the events that caused Proceed to Test Step 4.
the engine to stall.
Result: The operator is not operating the engine correctly.
B. Delayed engine shutdown (DES) may not have completed.
Repair: Operate the engine correctly.
(continued)
234 M0070030-01
(Table 140, contd)

4. Fuel Fuel Result: The engine is out of fuel.
A. Check the engine fuel supply. Repair: Supply the engine with an adequate fuel supply.
Result: The engine is not out of fuel.
5. Mechanical Failure Mechanical Result: A mechanical failure has occurred.

Failure
A. Check for a mechanical failure. Repair: Diagnose the problem and then repair the problem.
6. Activated Shutdown Switch Switch Result: The emergency stop shutdown was activated.
A. Interview the operator and determine the reason for the emer- Repair: Diagnose the problem and then repair the problem.
gency stop shutdown.
Result: The emergency shutdown was not activated.
7. Check the Emergency Shutdown Switch Circuit Emergency Result: The emergency stop shutdown switch is not operat-
Shutdown ing properly or there is a problem with the emergency shut-
A. Inspect the stop switches for evidence of damage that has been Switch down circuit.
caused by vibration, moisture, or corrosion. Circuit
Repair: Repair or replace the failed component.
B. Check the circuit for the shutdown switch. Refer to Trouble-
shooting, “Shutdown (Ground Level) - Test”. Verify that the repair eliminated the problem.
i06668937 • Circuit protection
Engine Shutdown Occurs • Engine speed/timing
Intermittently Table 141

J1939 Code PDL Code

Note: Use this procedure only if the engine shuts 3714-31 E992 (3)
down completely during operation.
3715-31 E991 (3)
Probable Causes 3719-0 E995 (3)
• Air shutoff 3719-16 E995 (2)
• Active codes and logged codes 5246-0 E1389 (3)
- E265 (1)
• Unstable fuel supply
• Electrical connections
(continued)
• Switches
M0070030-01 235
(Table 141, contd)

- E265 (2)
- E265 (3)
5272–31 E268 (3)
5272–31 E369 (3)
Recommended Actions
Table 142
1. Air Shutoff Air Shutoff Result: The air shutoff system is operating properly.
A. Check the operation of the air shutoff system. Proceed to Test Step 2.
Result: The air shutoff system is not operating properly.
Repair: Repair the air shutoff system. Refer to Troubleshoot-

ing, “Air Shutoff - Test” for troubleshooting information.
2. 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. Troubleshoot any codes nostic trouble codes before continuing with this procedure.
that are present prior to continuing with this procedure.
Result: There are no associated diagnostic trouble codes ac-
B. Using the electronic service tool, check for associated diag- tive or logged.
nostic trouble codes. Refer to Table 141 .
3. Electrical Connections Connectors Result: There are suspect connectors.
A. Check for the correct installation of the ECM J1/P1 and the Repair: Repair connectors that are suspect or replace con-
J2/P2 connectors. Check for correct installation of the fuel injec- nectors that are suspect.
tor connectors.
Perform the “Wiggle Test” on the electronic service tool.
Result: There are no suspect connectors.
(continued)
236 M0070030-01
(Table 142, contd)

4. Unstable Fuel Supply Fuel Result: The fuel quality is OK.
If there is an immediate engine shutdown, troubleshoot the elec- Proceed to Test Step 5.
trical connectors before proceeding with this procedure.
Result: The fuel quality is not OK.
A. Inspect the fuel system. Refer to Systems Operation, Testing
and Adjusting, “Fuel System - Inspect” for additional information. Repair: Replace the fuel. Verify that the repair eliminated the
problem.
Refer to the engine Operation and Maintenance Manual for in-
formation on improving the characteristics of the fuel during
B. Check fuel quality. Check the fuel tank for debris or foreign
objects which may block the fuel supply.
C. Check the filtered fuel pressure whilst the engine is being

cranked.
5. 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 6.
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 problem.
6. Switches Switches Result: The shutdown switches and wiring are OK.
A. Check the keyswitch input to the ECM. Proceed to Test Step 7.
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

7. 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 fuses (if equipped). Prior to re-
turning the engine to service, determine the condition that
B. Check the device for circuit protection. caused the circuit breaker to trip. Make the necessary repairs.
Result The circuit protection device is not tripped.
8. Engine Speed/Timing Speed/Timing Result: The Speed/Timing sensor circuit is not operating
properly.
A. Thoroughly inspect the connectors for the engine speed/tim-
ing sensors. Repair: Make the necessary repairs, Verify that the repair
eliminated the problem. Refer to Troubleshooting, “Speed/
B. Crank the engine, if the engine starts and no speed timing co- Timing `- Test”
des are logged, the speed timing circuit is operating properly.
M0070030-01 237
i06668971
Engine Shutdown While Idling

is active. Refer to Troubleshooting, “Event Codes” for
Table 143
Description
The engine has been idling for an extended amount of time.
This notification is for the operator. This notification is not a sus-
593-31 E1171 (1) Engine Idle Shutdown Occurred
pected engine problem.
The code is logged.
The engine is preparing to shut down because of an extended

Engine Idle Shutdown Driver
594-31 E1172 (2) non-working idle time.
Alert Mode
The code is logged.
The engine is shutting down.

Engine Idle Shutdown Driver
594-31 E1172 (3) An alarm is activated.
Alert Mode
The code is logged.
Probable Causes
• Extended idle time
Recommended Actions
steps are listed.
Table 144
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.
i06255977 Probable Causes

Engine Stalls at Low RPM • Active codes and logged codes
• Incorrect parameters
Note: Refer to Troubleshooting, “Service Tool • Air shut-off system

238 M0070030-01
• Low-pressure fuel system

• Fuel injectors
• Engine accessories
• Parasitic loads
Recommended Actions
Table 145
1. Active Codes and Logged Codes Diagnostic Result: A code is active or logged.
code
A. Establish communication between the electronic service tool and Repair: Troubleshoot any active codes before continuing
the Electronic Control Module (ECM) . Refer to Troubleshooting, with this procedure.
Result: A code is not active or logged.
B. Determine if a code is active or logged.
2. Incorrect Parameters Parameters Result: The correct parameters are being used.
A. Use the electronic service tool to verify that the correct parame- Proceed to Test Step 3.
ters are being used. Refer to Troubleshooting, “Configuration Pa-
rameters” for additional information. Result: The correct parameters are not being used.
Repair: Configure the correct parameters.
3. Air Shutoff System (if equipped) Air shutoff Result: The air shutoff is operating correctly.
A. Check for proper operation of the air shutoff system. Refer to Proceed to Test Step 4.
Troubleshooting, “Air Shutoff - Test”.
Result: The air shutoff is not operating correctly.
Repair: Make the necessary repairs. Verify the repair.
(continued)
M0070030-01 239
(Table 145, contd)

4. Low Pressure Fuel System Fuel system Result: The fuel system is operating properly.
A. Visually check the fuel level in the fuel tank. Do not rely on the Proceed to Test Step 5.
fuel gauge only.
Result: The fuel system is not operating properly.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position. Repair: Make the necessary repairs. Verify that the re-
pair eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Testing and
Adjusting, “Fuel System - Inspect” for additional information.
Cold weather adversely affects the characteristics of the fuel. Refer

to the engines Operation and Maintenance Manual for information
on improving the characteristics of the fuel during cold-weather
operation.
D. Check fuel quality. Check the fuel tank for debris or foreign ob-
jects which may block the fuel supply.
E. Check the filtered fuel pressure while the engine is being

cranked. Refer to Troubleshooting, “Fuel Pressure Is Low” for the
proper testing procedure.
5. Fuel Injectors Diagnostic Test Result: The test was successful.
If service has been performed on the engine fuel system recently, Proceed to Test Step 6.
verify that the injector trim files are correct. Use the electronic serv-
ice tool to check that the injector trim files are correct for the injec- Result: The test was not successful.
tors that are installed on the engine.
A. Perform the “Injector Solenoid Test” on the electronic service tool problem.
in order to determine if all of the injector solenoids are being ener-
gized by the ECM. Reset all active codes and clear all logged codes.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests” under Verify that the repair eliminated the problem.
the “Diagnostics” menu.

service tool.
6. Engine Accessories Engine Result: An engine accessory is creating an excessive

accessories load.
A. Inspect any engine accessories and the transmission (if
applicable). Repair: Repair the engine accessory.
240 M0070030-01

steps are listed.
i06669004
Engine Top Speed Is Not

Obtained
Note: If this fault occurs only under load, refer to

Troubleshooting, “Acceleration Is Poor or Throttle
Response Is Poor”.
Table 146
J1939 Code PDL Code

5580-17 E198 (1)
5580-18 E198 (2)
Probable Causes
• Incorrect parameters
• Accessory and/or parasitic loads

• Incorrect flash file
• Restriction in the air inlet and exhaust system

• Proper operation of the turbocharger
• Low-pressure fuel system
• Fuel injectors
Recommended Actions
steps are listed.
M0070030-01 241
Table 147
A. Establish communication between the electronic service Repair: Troubleshoot any active codes before continuing with
tool and the Electronic Control Module (ECM). Refer to Trou- this procedure.
B. Use the electronic service tool to check for active or re- Proceed to Test Step 2.
cently logged diagnostic codes.
2. Incorrect Parameters Parameters Result: The parameters are configured correctly.
A. Use the electronic service tool to verify that the correct en- Proceed to Test Step 3.
gine parameters are being used. Refer to Troubleshooting,
“Configuration Parameters” for additional information. Result: The parameters are not configured correctly.
B. Verify that all the parameters for parasitic loads are Repair: Correctly configure the parameters.
correct.
3. Accessory and/or Parasitic Loads Parasitic Loads Result: There is not an excessive load on the engine.
A. Check all accessory equipment for problems that may cre- Proceed to Test Step 4.
ate excessive load on the engine.
Result: There is an excessive load on the engine.
B. Check for any excess parasitic load on the engine.
4. Incorrect Flash File Flash File Result: The latest flash file is installed in the ECM.
A. Verify that the latest flash file is installed in the Electronic Proceed to Test Step 5.
Control Module (ECM). Refer to Troubleshooting, “ECM Soft-
ware - Install” for the proper procedure. Result: The latest flash file is not installed in the ECM.
Repair: Install the latest flash file. Verify that the repair elimi-
nated the problem.
5. Restriction in the Air Inlet and Exhaust System Restrictions Result: There are restrictions in the air inlet or exhaust
system.
A. Check the air filter restriction indicator, if equipped. Clean
plugged air filters or replace plugged air filters. Refer to the Repair: Make the necessary repairs, Verify that the repair
Operation and Maintenance Manual. eliminated the problem.
B. Check the air inlet and exhaust system for restrictions Result: There are no restrictions in the air inlet or exhaust
and/or leaks. system.
(continued)
242 M0070030-01
(Table 147, contd)

6. Proper Operation of the Turbocharger Turbocharger Result: The turbocharger is operating properly.
A. Check for proper operation of the turbocharger. Proceed to Test Step 7.
Result: The turbocharger is not operating properly.
Repair: Repair or replace the turbocharger. Verify that the re-

pair eliminated the problem.
7. Low-Pressure Fuel System Fuel System Result: The fuel system is operating properly.
A. Visually check the fuel level in the fuel tank. Do not rely on Proceed to Test Step 8.
the fuel gauge only.
OPEN position. Repair: Make the necessary repairs. Verify that the repair
eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation, Test-
ing and Adjusting, “Fuel System - Inspect” for additional
information.

Refer to the engines Operation and Maintenance Manual for
information on improving the characteristics of the fuel during
D. Check fuel quality. Check the fuel tank for debris or foreign
objects which may block the fuel supply.
E. Check the filtered fuel pressure whilst the engine is being

cranked. Refer to Troubleshooting, “Fuel Pressure Is Low”
for the proper testing procedure.
8. Fuel Injectors Injector Solenoid Result: The test was successful.

Test or Fuel Sys-
If service has been performed on the engine fuel system re- tem Verification Return the unit to service.
cently, verify that the injector trim files are correct. Use the Test
electronic service tool to check that the injector trim files are Result: The test was not successful.
correct for the injectors that are installed on the engine.
A. Perform the “Injector Solenoid Test” on the electronic serv-
ice tool to determine if all the injector solenoids are being Reset all active codes and clear all logged codes.
energized by the ECM.
C. Perform the “Automatic Cylinder Cutout Test” on the elec-

M0070030-01 243
i06255992
Engine Vibration Is Excessive
Probable Causes
• Inspect the vibration damper.
• Engine supports
• Driven equipment
• Engine misfiring
• Running rough
244 M0070030-01
Recommended Actions
Table 148
1. Inspect the Vibration Damper Damper Result: The vibration damper or the mounting bolts are
damaged.
A. Clean any debris from around the damper. Check the vibration
damper for damage. Repair: Replace the damaged vibration damper or the dam-
aged mounting bolts.
B. Inspect the mounting bolts for damage and/or for wear. Refer to
the Disassembly and Assembly manual. Result: The vibration damper or the mounting bolts are not
damaged.
2. Engine Supports Engine Result: The mounts and brackets are loose and/or broken.
Supports
A. Inspect the mounts and the brackets while you run the engine Repair: Replace the mounts and brackets that are loose
through the speed range. Look for mounts and brackets that are and/or broken.
loose and/or broken.
Result: The mounts and brackets are not loose and/or
B. Check the alignment of the following before operating the en- broken.
gine under load for any length of time:
1. Mounts
2. Coupling
3. Driven Equipment Driven Result: The driven equipment and the alignment are OK.
equipment
A. Inspect the mounting bolts for the driven equipment. Inspect the Repair: Refer to Troubleshooting, “Engine Misfires, Runs
alignment and the balance of the driven equipment. Rough, or Is Unstable”, for more troubleshooting
information.
B. Inspect the coupling.
Result The driven equipment and the alignment are not OK.
Repair: Repair or replace the driven equipment.
Complete the procedure in the order in which the • Failed Diesel Particulate Filter (DPF)
steps are listed.
i06669032
Exhaust Has Excessive Black

Smoke
Check for the following problems if there is excessive

black exhaust smoke.
Probable Causes
Note: An engine with a Diesel Particulate Filter
(DPF) that has been removed will emit black smoke.
M0070030-01 245
Recommended Actions
Obvious failure of a DPF
steps are listed.
Table 149
1. Failed DPF DPF Result: There are no signs of failure.
The outlet side of the DPF is the only side that can be used to Repair: Reinstall the DPF.
determine a failure.
A. Remove the DPF and check for signs of a failure. Refer to
Illustration 86 for an example of an obvious failure. Most fail- Result: There are signs of failure.
ures are not obvious.
Repair: Reinstall the failed DPF and Proceed to Test Step 2.
2. Diagnostic Codes Codes Result: There are no codes present.
A. Check for any logged or active codes associated with high Proceed to Test Step 3.
soot loading.
Result: There are codes present.
Repair: Troubleshoot the codes before continuing with this

procedure.
(continued)
246 M0070030-01
(Table 149, contd)

3. Perform the Automatic Cylinder Cutout Test using the Cylinder Cutout Result: The test was successful.
Electronic Service Tool Test
A. Perform the Automatic Cylinder Cutout Test.
Result: The test was not successful.
Repair: Make the necessary repairs, Proceed to Test Step 6.
4. Check for Boost Pressure Leaks Leaks Result: There are leaks found.
A. Check for boost pressure leaks. Repair: Repair the boost pressure leaks. Proceed to Test Step
6.
Result: There are no leaks found.
5. Inspect the Turbocharger Turbocharger Result: The turbocharger is OK.
A. Check for boost pressure leaks. Proceed to Test Step 6.
Refer to Testing and Adjusting, “Turbocharger - Inspect” for

additional information. Result: The turbocharger is not OK.
Repair: Replace the turbocharger and Proceed to Test Step

6.
6. Perform the ARD Ignition Test ARD Ignition Result: The test was successful.
Test
A. Perform an ARD ignition test using the electronic service Return the unit to service.
tool to verify the correct operation of the Clean Emissions
Module (CEM).
The ASH model must be reset if a new DPF is installed.
B. If the DPF has failed, replace the DPF. Reset the ASH
model in the electronic service tool. Refer to Troubleshooting,
“Service Tool Features, DPF ASH Service” for additional
information.

Exhaust Has Excessive White
Smoke Probable Causes
• Active codes
• Oil in the exhaust system
Note: Some white smoke may be present during cold
start-up conditions when the engine is operating • Cold mode operation (if applicable). Refer to
normally. If the white smoke persists, there may be a "Cold Mode Operation" within the Systems
problem. Operation, “General Information”.
• Starting aids (if applicable)
M0070030-01 247
• Noncurrent flash file

• Cooling system
• Unstable fuel supply

• Unstable fuel injection
Recommended Actions
steps are listed.
Table 150
1. Active Codes and Logged Codes Diagnostic Code 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.
2. Oil in the Exhaust System Oil in the Exhaust Result: The exhaust system contains oil.
System
A. Check for oil in the exhaust system. Repair: Determine the cause of oil in the exhaust sys-
tem and make the necessary repairs.
Result: The exhaust system does not contain oil.
3. Clean Oil from the Exhaust System Oil in the Exhaust Result: Oil has been cleaned from the exhaust system
System and the white smoke has dissipated.
A. Remove excess oil from piping with a clean cloth.
B. Inhibit regeneration with the inhibit switch.
Result: Oil has been cleaned from the exhaust system
C. Operate the engine at elevated idle (1500 RPM) for 10 but the white smoke did not dissipate.
minutes.
(continued)
248 M0070030-01
(Table 150, contd)

4. Clean Oil from the Aftertreatment System Oil in the After- Result: Oil has been cleaned from the aftertreatment
treatment System system and the white smoke has dissipated.
A. Shut off the engine
B. Remove the DPF center section, let the DPF drain on the inlet
side overnight. Result: Oil has been cleaned from the aftertreatment
system but the white smoke did not dissipate.
C. Remove the DOC, let the DOC drain on the outlet side
overnight For further assistance, confer with the Dealer Solutions
Network (DSN).
D. Once drained, install the DPF and DOC
E. Operate the engine at elevated idle (1500 RPM) for 10 minutes.
5. Cold Mode Operation (if applicable) Cold Mode Result: The engine is operating in cold mode.
During cold mode operation, condensation may be present and is This situation is normal operation. Return the engine to
normal. service.
A. Cold mode is activated whenever the engine coolant tempera- Result: The engine is not operating in cold mode.
ture falls below a predetermined value. Monitor the status screen
on the electronic service tool to verify that the engine has exited Proceed to Test Step 6.
cold mode. Observe the reading for coolant temperature on the
6. Starting Aids (If Applicable) Starting Aid Result: The starting aid is operating correctly.
A. If cold ambient conditions exist, check operation of starting Proceed to Test Step 7.
aids. Verify that the starting aid is operating correctly. Refer to the
appropriate circuit test for information that is related to trouble- Result: The starting aid is not operating correctly.
shooting the starting aid.
Repair: Make the necessary repairs. Verify that the re-
If ether bottles are not installed, check the configuration screen on pair corrected the problem.
the electronic service tool to verify that ether is not enabled.
7. Noncurrent Flash File Flash File Result: The latest flash file is installed.
A. Verify that the latest flash file is installed in the ECM. Refer to Proceed to Test Step 8.
Troubleshooting, “ECM Software - Install” for the proper
procedure. Result: The latest flash file is not installed.
Repair: Install the latest flash file. Verify that the repair
eliminates the problem.
(continued)
M0070030-01 249
(Table 150, contd)

8. 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 problem.
“Cooling System”.
Result: There is not an internal coolant leak.
Check for leakage at the ARD Nozzle Heater O-rings. If the O-
rings are leaking coolant, replace the ARD head. Proceed to Test Step 9.
B. Check the NRS cooler for leaks. Refer to Testing and Adjusting,
“Exhaust Cooler (NRS) - Test”.
9. Unstable Fuel Supply Fuel System Result: The fuel system is operating properly.
A. Visually check the fuel level in the fuel tank. Do not rely on the Proceed to Test Step 10.
fuel gauge only.
OPEN position. Repair: Make the necessary repairs. Verify that the re-
pair eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation, Testing
and Adjusting, “Fuel System - Inspect” for additional information.
Cold weather adversely affects the characteristics of the fuel. Re-

fer to the engines Operation and Maintenance Manual for informa-
tion on improving the characteristics of the fuel during cold-
weather operation.
D. Check fuel quality. Check the fuel tank for debris or foreign ob-
jects which may block the fuel supply.
E. Check the filtered fuel pressure when the engine is being

cranked. Refer to Troubleshooting, “Fuel Pressure Is Low” for the
proper testing procedure.
10. Fuel Injectors Injector Solenoid Result: The test was successful.
Test or Fuel Sys-
If service has been performed on the engine fuel system recently, tem Verification Return the unit to service.
verify that the injector trim files are correct. Use the electronic Test
service tool to check that the injector trim files are correct for the Result: The test was not successful.
injectors that are installed on the engine.
A. Perform the “Injector Solenoid Test” on the electronic service problem.
tool to determine if all the injector solenoids are being energized
by the ECM. Reset all active codes and clear all logged codes.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests” Verify that the repair eliminated the problem.

service tool.
250 M0070030-01
i06669131
Exhaust System Contains

Coolant
Use the following procedure to troubleshoot a

problem with coolant in the exhaust system.
Probable Causes
• NOx Reduction System cooler leak
• Aftertreatment Regeneration Device (ARD) head

leaking coolant
• Cylinder head gasket leak
• Cylinder head leak
Recommended Actions
Note: After the repair has been made, an
Aftertreatment System Functional Test must be
performed using the electronic service tool. The test
will verify the proper functionality of both NOx
sensors.
Table 151
1. NRS cooler NRS Cooler Result : The NRS cooler has a leak.
A. Check the NRS cooler for leaks for utilizing the “On Engine Repair: Replace the NRS cooler. Refer to the Disassembly
Test Procedure” . Refer to Testing and Adjusting, “Exhaust and Assembly manual for the correct procedure.
Cooler (NRS) - Test”.
Proceed to Step 5.
Result : The NRS cooler does not have a leak.
2. Check the ARD head Coolant Leak Result : The ARD head is leaking coolant.
A. Pressurize the cooling system. Refer to Systems Opera- Repair: Replace the ARD head. Refer to the Disassembly
tion, Testing and Adjusting, “Cooling System - Test” for the and Assembly manual for the correct procedure.
correct procedure.
B. Remove the ARD head. Refer to the Disassembly and As-
sembly manual for the correct procedure. Result : The ARD head is not leaking coolant.
C. Inspect the combustion canister for signs of coolant leaking Proceed to Test Step 3.
from the ARD nozzle heater O-ring seals.
(continued)
M0070030-01 251
(Table 151, contd)

3. Cylinder head gasket leak Cylinder Head Result : The cylinder head gasket is leaking.
Gasket
A. Check the cylinder head gasket for leaks. Refer to the Sys- Repair: Replace the cylinder head gasket. Refer to the Disas-
tems Operation, Testing and Adjusting for the proper proce- sembly and Assembly manual.
dure for checking the cylinder head.
Result : The cylinder head gasket is not leaking.
4. 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 and/or replace the cylinder
on the cylinder head. Refer to the Systems Operation, Testing head. Refer to the Disassembly and Assembly manual.
and Adjusting for the proper procedure for checking the cylin-
der head. 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 to the “Engine #1 Aftertreatment Controller” using Result : The test is not successful.
There are additional diagnostic codes.
Repair: Troubleshoot the additional codes. Refer to the Trou-
D. Perform the “Aftertreatment System Functional Test” . bleshooting manual for the correct procedure.
i06669808
Exhaust System Contains Fuel
Probable Causes
• Short circuit in the ARD fuel pump relay wiring
• Corrosion in the wiring harness connectors for the

ARD fuel pump relay
• Failed ARD fuel pump relay
252 M0070030-01
Recommended Actions
Tier 4 Final Schematic

steps are listed.
Carefully following this procedure is a good way to
identify wiring problems.
M0070030-01 253
Table 152
1. Inspect the Components Damaged Wiring Result: There is a problem with the wiring or a
or Connectors connector.
A. Visually inspect the components for the ARD fuel pump system.
Look for the following problems: Repair: Repair the wiring or connector. Replace parts, if
necessary.
Result: The wiring is OK.
3. Damage that is caused by excessive heat
2. Check for Voltage at the Coil for the ARD Fuel Pump Relay Voltage Result: There is voltage between the relay coil and a
good ground source.
There is a short from a power source in the wiring har-
B. Measure voltage between the relay coil and a good ground ness or there is moisture or corrosion in a connector be-
source. tween the ECM and ARD fuel pump relay coil.
There should not be voltage on the relay coil when the keyswitch Make the necessary repairs.
is in the OFF position. Low amounts of voltage can keep the relay
pulled in after the keyswitch has been turned to the OFF position. Proceed to Test Step 4.
Result: There is not voltage between the relay coil and a

good ground source.
(continued)
254 M0070030-01
(Table 152, contd)

3. Check for Voltage at the Load Side of the ARD Fuel Pump Voltage Result: There is voltage between the load side of the
Relay ARD fuel pump relay and a good ground source.
A. Turn the keyswitch to the OFF position. Remove the relay. Check for voltage between the load
side of the ARD fuel pump relay and a good ground
B. Measure voltage between the load side of the ARD fuel pump source.
relay and a good ground source.
If voltage is present, there is a short in the wiring between
the relay and the ARD fuel pump. Repair or replace the
wiring.
If voltage is not present, the relay has failed.
Repair: Replace the relay.
Result: There is not voltage between the load side of the

ARD fuel pump relay and a good ground source.
For further assistance, confer with the Dealer Solutions

Network (DSN).
4. Clean Fuel from the Exhaust System Excess Fuel Result: The excess fuel and white smoke did not return
after operating the engine for 20 minutes.
A. Remove excess fuel from the piping with a clean cloth.
Repair: Perform a Manual DPF Regeneration using the
B. Inhibit regeneration with the inhibit switch. electronic service tool.
C. Operate the engine at elevated idle (1500 RPM) for 20 minutes. Return the unit to service.
Result: The excess fuel and white smoke returned after

operating the engine for 20 minutes.
For further assistance, confer with the Dealer Solutions

Network (DSN).
i06256044 Recommended Actions

Exhaust System Contains Oil Note: After the repair has been made, the oil should
be cleaned from the exhaust system. To clean the oil
from the exhaust system, perform the following
procedure:
Probable Causes 1. Remove excess oil from piping with a clean cloth.
• Failed turbocharger seals 2. Inhibit regeneration with the inhibit switch.
• Worn valve guide seals or faulty valve guide seals 3. Operate the engine at elevated idle (1500 RPM)
for 10 minutes.
• Worn valve guides If white smoke dissipates, return machine to work.
• Worn piston rings If white smoke persists, this is an indication of a
saturated aftertreatment system, perform the
• Extended idle times following procedure:
1. Shut off the engine.
2. Remove the DPF center section, let the DPF drain
on the inlet side.
M0070030-01 255
3. Remove the DOC, let the DOC drain on the outlet

side overnight .
4. Once drained, install the DPF and DOC.
5. Operate the engine at elevated idle (1500 RPM)
for 10 minutes.
If white smoke dissipates, return machine to work.
If white smoke does not dissipate, Contact the Dealer
Solutions Network (DSN).
Table 153
1. 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. Verify the repair.
Result: Oil is not present in the inlet or exhaust manifold.
2. 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.
Result: The valve guide seals are not damaged.
3. 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.
Result: The valve guides are not worn.
4. Worn Piston Rings Piston rings Result The piston rings are worn.
A. Piston rings that have excessive wear can cause too much Repair: Replace the piston rings. Verify the repair.
pressure in the crankcase. The additional pressure in the crank-
case will cause more than the normal amount of crankcase blowby Result The piston rings are not worn.
from the crankcase breather.
B. Inspect piston rings
5. Extended Idle Times Idle times Result The idle times are extensive.
A. Extended idle times will allow oil to pass into the exhaust Repair: Reduce the idle times.
system.
256 M0070030-01

steps are listed.
i06671037
Exhaust Temperature Is High
The Engine Control Module (ECM) monitors the

following parameters to calculate an exhaust
temperature:
• Barometric pressure
• Intake manifold air temperature
• Engine speed
Certain operating conditions may cause the
calculated exhaust temperature to increase to a level
that may damage engine components. If a high
exhaust temperature occurs, the ECM derates the
engine to reduce the calculated exhaust temperature.
The engine is derated only to a level that allows the
calculated exhaust temperature to return to an
acceptable level.
Table 154
J1939 Code PDL Code

108-3 3528-3
108-4 3528-4
Note: The electronic service tool will report the status

for atmospheric pressure as the ambient barometric
pressure. The readings for the turbocharger inlet
pressure sensor will be approximately the same
value that is reported by the atmospheric pressure
sensor. The approximate same value readings will
occur when the engine is not running. If the readings
do not agree, troubleshoot the sensor circuit for the
suspect sensor. Refer to Troubleshooting, “Sensor
Signal (Analog, Active) - Test”.
Probable Causes
• Associated codes
• Boost Leak
• Engine operating conditions
• Failed exhaust balance valve

• High altitude
• Obstructed aftercooler
M0070030-01 257
Table 155
1. Check for Associated Diagnostic Codes Associated Di- Result: An associated diagnostic code is active or logged.
agnostic
A. Establish communication between the electronic service tool Codes Repair: Troubleshoot the associated code. Refer to Trou-
and the ECM . Refer to Troubleshooting, “Electronic Service bleshooting, “Diagnostic Trouble Codes” to troubleshoot the
Tools”, if necessary. associated diagnostic code.
B. Determine if a code is active or logged. Result: An associated diagnostic code is not active or
logged.
Table 156
DTC with associ- Data logged in this Interpretation
ated derate? histogram?
Derate was probably

caused by the ex-
No Yes
haust temperature
derate.
There may be multi-
ple causes for de-
rate since this
exhaust tempera-
ture histogram only
logs data when the
largest derate oc-
Yes Yes
curs. Another derate
may have been ac-
tive due to a diag-
nostic trouble code,
but a larger exhaust
temperature derate
was applied).
Derate was probably

not caused by the
Yes No
exhaust tempera-
ture derate.
258 M0070030-01
Example of 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 fault code will not be logged
when the system calculates a high exhaust temperature condition. An engine derate will be activated 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 informational if no diagnostic codes are
active or logged.
steps are listed.
M0070030-01 259
Table 157
2. Check for Boost Leakage Boost Leaks Result: Boost leakage was found.
A. Apply a light load to the engine and check for boost leakage. Repair: Repair the leaks. Return the unit to service.
Result: Boost leakage was not found.
3. Check the Engine Operating Conditions Normal Result: The code was logged during a heavy load.
Operation
A. Check the histogram to determine if the high exhaust tempera- Repair: Reduce the load on the engine. Return the unit to
ture was due to normal operation. service.
When possible, interview the operator. Determine if the engine is
being operated under heavy load. Ensure that the engine is being Result: The code was not logged during a heavy load.
operated at the proper engine speed.
If derates are suspected, reset histogram and return the unit to
service. If the histogram repopulates without fault codes, the en-
gine derate was under normal engine operation.
4. Check the Exhaust Balance Valve Failed Exhaust Result: The exhaust balance valve has failed.
Balance Valve
A. An exhaust balance valve that has failed in the closed position Repair: Repair or replace the balance valve. Return the unit
can cause high exhaust temperatures. Refer to Troubleshooting, to service.
“Exhaust Balance Valve - Test” for the correct troubleshooting
procedure. Result: The exhaust balance valve has not failed.
5. 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.
High altitudes can cause high exhaust temperatures, consider the
operational altitude when troubleshooting a high exhaust temper- Result: The engine was not operating at high altitudes.
ature. High exhaust temperatures are associated with high opera-
tional altitudes. Proceed to Test Step 6.
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.
6. Check for an Obstructed Aftercooler Obstructed Result: The engine aftercooler 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 aftercooler is obstructed. Check the aftercooler for
obstructions or debris. Ensure that the flow of air or coolant
through the aftercooler is adequate.
260 M0070030-01
i06671043
Fuel Consumption Is
Excessive

Probable Causes
• Engine operation
• Diagnostic codes, event codes and derates
• Fuel quality
• Fuel injection
• Engine speed/timing
• Air inlet and exhaust system
• Check for damaged accessory equipment
Recommended Actions
steps are listed.
Table 158
1. Engine Operation Operation Result: Excessive idling is indicated.
Use the electronic service tool to check the “Current Totals” for ex- Repair: Make the necessary changes. Ensure that the
cessive idle time and/or for a high load factor. Excessive idle time problem is resolved.
and/or for a high load factor would be indicative of poor operating
habits. Result: Excessive idling is not indicated.
Note: Fuel consumption may also be affected by

environmental conditions such as wind and snow.
Table 159
2. Diagnostic Codes, Event Codes and Derates Codes and Result: Codes are active.
Derates
Certain diagnostic codes and/or event codes may cause poor Repair: Troubleshoot the codes that are present.
performance. Proceed to Test Step 3.
A. Connect the electronic service tool to the engine ECM. Result: No codes are active.
B. Use the electronic service tool to check for active diagnostic co- Proceed to Test Step 3.
des. Wait at least 30 seconds in order for any codes to become
active.
M0070030-01 261
Note: Certain failure modes of a sensor may produce

an output signal that does not represent an accurate
measurement. The inaccurate measurement can
occur when the signal is in the operational range of
the sensor. Use the electronic service tool to check
that the pressures and the temperatures are
fluctuating normally. Also check that the values are
reasonable for the conditions that are present.
Table 160
3. Fuel Quality Poor Fuel Quality Result: Fuel quality is undesirable.
A. Check fuel quality. Repair: Refer to the Operation and Maintenance Man-
ual for information on improving the characteristics of
Cold weather adversely affects the characteristics of the fuel. the fuel during cold-weather operation. Ensure that the
Result Fuel quality is desirable.
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.
Table 161
4. Fuel Injection Fuel Injection Result The “Fuel System Verification Test” failed.
A. Perform the “Fuel System Verification Test” in the electronic Repair: Diagnose the problem and then repair the
service tool. Refer to Troubleshooting, “Injector Solenoid - Test”. problem. Clear all logged diagnostic codes. Verify that
the repair eliminated the problem.
Result The “Fuel System Verification Test” completed

successfully.
5. Engine Speed/Timing Engine Speed/ Result The speed/timing sensor calibration failed.
Timing
A. Perform a speed/timing sensor calibration. Refer to the calibra- Repair: Resolve the issue. Ensure that the problem is
tion procedure Troubleshooting, “Timing - Calibrate”. resolved.
Result The speed/timing sensor calibration completed

successfully.
(continued)
262 M0070030-01
(Table 161, contd)
6. Air Inlet and Exhaust System Air inlet and Ex- Result The air inlet and exhaust system is not func-
haust System tioning correctly.
A. Inspect the air filter for a restriction. If the air filter shows signs
of plugging, clean the air filter or replace the air filter. Repair: Make the proper repairs. Ensure that the
B. Check the air inlet and exhaust system for restrictions and/or for
leaks. Refer to Systems Operation, Testing and Adjusting. Result The air inlet and exhaust system is functioning
correctly.
C. Check the turbocharger and exhaust balance valve. Refer to
Troubleshooting, “Exhaust Balance Valve - Test”. Proceed to Test Step 7.
7. Check for Damaged Accessory Equipment Damaged Acces- Result Problems have been found with the accessory
sory Equipment equipment.
A. Check all accessory equipment for problems that may create
excessive load on the engine. Repair: Repair any damaged components or replace
any damaged components.
Result No problems have been found with the acces-

sory equipment.
i06671060
Fuel Filter Is Restricted
The Electronic Control Module (ECM) detects an

abnormal fuel filter differential pressure.
is active. Refer to Troubleshooting, “Event Codes” for
information about event codes. For information on
the engine monitoring system, refer to

Table 162

The code is logged.
5584-15 E390 (1) Fuel Filter Restriction The filter is becoming clogged. Change the filter at the next regu-
lar maintenance.
The code is logged.
The difference between the filtered fuel pressure and the unfil-
5584-16 E390 (2) Fuel Filter Restriction tered fuel pressure is greater than the trip point pressure.
The engine ECM will derate engine power.
Change the fuel filter.
Probable Causes Note: Change the primary filter, the secondary filter,
and the tertiary filter at the same time. Use clean fuel
Fuel Filter on the stud threads of filter base to reduce friction.
• Fuel filter
M0070030-01 263
Note: Do not fill the canister or the fuel filter

before installation. The fuel can carry debris into
the fuel filter and the fuel system may be
damaged. The electric priming pump is designed
to purge the trapped air in the new filters.
steps are listed.
Table 163
1. Change the Fuel Filters Fuel Filter Result: The code is no longer active
Change
A. Reset all active codes and clear all logged codes by cycling the Result: The event code becomes active after changing
keyswitch to the OFF position. Change the primary fuel filter. the fuel filters.
B. Prime the system with the electric priming pump. Repair: The problem may be electrical. Refer to Trouble-
shooting, “Sensor Signal (Analog, Active) - Test” for the
C. Start the engine and allow the engine to idle for few minutes. procedure to troubleshoot the circuit.
D. Turn the engine OFF and change the secondary fuel filter.
E. Prime the system with the electric priming pump.
F. Start the engine and allow the engine to idle for few minutes.
G. Turn the engine OFF and change the tertiary fuel filter.
H. Prime the system with the electric priming pump.
J. Restart the engine.
i06671209
Fuel Pressure Is High
The probable causes of high fuel pressure
• Fuel pressure sensor
• Fuel lines
• Fuel transfer pump
• Fuel return pressure regulator
Note: High fuel pressure may cause high fuel

temperatures. Troubleshoot a code for high fuel
pressure before troubleshooting a code for high fuel
temperature.
Use this procedure to troubleshoot high fuel
pressure. Use this procedure if one of the following
event codes is active. Refer to Troubleshooting,
“Event Codes” for information about event codes. For
information on the engine monitoring system, refer to
264 M0070030-01
Table 164

5580–16 E096 (2) High Fuel Pressure The code is logged.

The fuel pressure is above the
trip point pressure.
Table 165
1. Determine the Code Diagnostic trou- Result: An E096 (2) or 5580-16 code is present.
ble code
A. Connect the electronic service tool to the service tool connector. Proceed to Test Step 2.
Refer to Troubleshooting, “Electronic Service Tools”, if necessary.
Result: A code other than E096 (2) or 5580-16 code is
B. Determine if a diagnostic trouble code is present. present.
Troubleshoot the code. Refer to the correct trouble-

shooting procedure.
(1) Fuel temperature sensor (2) Fuel sampling port
M0070030-01 265
(3) Fuel pressure sensor (4) Secondary fuel filter base
Do not use the fuel sampling port (2) for

measuring the pressure. Follow the steps below.
Table 166
2. Check the Fuel Pressure Sensor Fuel pressure Result: The gauge value of the fuel pressure is within
137 kPa (20 psi) of the fuel pressure reading shown in
A. Record the fuel pressure from the electronic service tool. Re- the electronic service tool.
cord the data in Table 167 .
B. Remove the fuel pressure sensor (3).
Result: The gauge value of the fuel pressure is not within
C. Install a suitable pressure gauge into the low-pressure fuel sys- 137 kPa (20 psi) of the fuel pressure reading shown in
tem with a tee fitting in the port for the fuel pressure sensor. the electronic service tool.
D. Connect the fuel pressure sensor to the tee fitting. Repair: Replace the pressure sensor. Reset all active co-
des and clear all logged codes by cycling the keyswitch to
E. Monitor the status for “Fuel Pressure” on the electronic service the OFF position. Verify that the problem has been
tool. resolved.
F. Crank the engine. If the problem is not resolved, proceed to Test Step 3.
After the pressure sensor is removed, a code for low fuel pressure
will become active. Reset all active codes and clear all logged co-
des by cycling the keyswitch to the OFF position, after the sensor
is reinstalled.
G. Compare the pressure reading on the gauge to the pressure

reading on the electronic service tool.
Table 167
Engine RPM Fuel pressure from Fuel pressure from
the Electronic Serv- the mechanical
ice Tool gauge
800
1800
266 M0070030-01
Fuel supply lines
M0070030-01 267
Return fuel line
Table 168
3. Inspect the Fuel Supply Lines Restrictions, Result: The fuel lines and the cooler (if equipped) are
pinching, and OK.
A. Visually inspect the fuel lines between the primary filter base swelling
and the inlet to the cylinder head. Also, inspect the fuel cooler, if Proceed to Test Step 4.
equipped. Inspect the fuel return line from the head to the fuel
tank. Inspect the lines for restrictions, pinching, and swelling. Result: The fuel lines and the cooler (if equipped) are
not OK.
Repair: Make the necessary repairs. Reset all active

codes and clear all logged codes by cycling the key-
switch to the OFF position. Verify that the problem has
been resolved.
268 M0070030-01
(5) Return fuel pressure regulator
Table 169
4. Replace the Return Fuel Pressure Regulator Fuel pressure Result: The regulator was replaced. Reset all active
regulator codes and clear all logged codes by cycling the key-
A. Replace the fuel pressure regulator. switch to the OFF position. Verify that the problem is
resolved.
M0070030-01 269
Typical fuel transfer pump
(6) Relief valve
Table 170
5. Inspect the Relief Valve for the Fuel Transfer Pump Relief valve Result: The relief valve is stuck CLOSED.
A. Inspect the relief valve for the transfer pump. The spring must Repair: Replace the fuel transfer pump. Reset all ac-
move freely. tive codes and clear all logged codes by cycling the
keyswitch to the OFF position. Verify that the problem
has been resolved.
Result: The relief valve is OK.
Repair: Clean the relief valve and reinstall the relief

valve. Reset all active codes and clear all logged codes
by cycling the keyswitch to the OFF position. Verify that
the problem has been resolved.
i06672053
Fuel Pressure Is Low
Note: The low fuel pressure code may activate when

the water separator is being drained. Disregard the
code and toggle the keyswitch to clear the code.
Use this procedure to troubleshoot a low fuel
pressure event. Use this procedure if one of the
following event codes is active.
270 M0070030-01
Table 171

Engine Filtered Fuel Delivery Absolute
5580-17 E198 (1) The code is logged.
The code is logged.

Engine Filtered Fuel Delivery Absolute The engine power is derated.
5580-18 E198 (2)
Pressure : Low - moderate severity (2) The Electronic Control Module (ECM) will illuminate the action
lamp.
Table 172
1. Determine the Code Codes Result: A diagnostic code listed in Table 171 is active.
Result: A diagnostic code other than those codes listed
B. Check for active diagnostic codes. in Table 171 is active.
Repair: Troubleshoot the additional diagnostic codes.

Refer to Troubleshooting, “Diagnostic Trouble Codes”.
2. Check the Fuel Level in the Tank Fuel level Result: The fuel level is OK.
A. Visually inspect the fuel level in the fuel tank. Ensure that the fuel Proceed to Test Step 3.
tank contains enough fuel to operate the engine.
Result: The fuel level is not OK.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position. Repair: Fill the tank. Verify that the problem has been
resolved.
3. Inspect the Fuel System for Leaks Leaks in the Result: No leaks were found.
fuel system
A. Perform a visual inspection of the fuel system. Verify that there Proceed to Test Step 4.
are no fuel leaks. Inspect the fuel lines from the fuel transfer pump
to the secondary fuel filter base for restrictions. Refer to Systems Result: Leaks were found in the fuel system.
Operation/Testing and Adjusting, “Fuel System - Inspect” for addi-
tional information. Repair: Repair the leaks. Verify that the problem is
resolved.
Note: Cold weather adversely affects the

characteristics of the fuel. Refer to the engine
Operation and Maintenance Manual for information
on improving the characteristics of the fuel during
M0070030-01 271
(1) Fuel temperature sensor (3) Fuel pressure sensor

(2) Fuel sampling port (4) Fuel filter base
Note: Do not use location (2) for measuring the fuel

pressure. Follow the steps below.
272 M0070030-01
Table 173
4. Verify the Operation of the Fuel Pressure Sensor Pressure Result: The gauge value of the fuel pressure is within
sensor 69 kPa (10 psi) of the fuel pressure reading shown in the
A. Turn the keyswitch to the OFF position. electronic service tool.
B. Remove the fuel pressure sensor. Proceed to Test Step 5.
C. Install a suitable pressure gauge into the low-pressure fuel sys- Result: The gauge value of the fuel pressure is not within
tem with a tee fitting in the port for the fuel pressure sensor. 69 kPa (10 psi) of the fuel pressure reading shown in the
D. Connect the fuel pressure sensor to the tee fitting.
Repair: Replace the pressure sensor. Verify that the
E. Monitor the status for “Fuel Pressure” on the electronic service problem has been resolved.
tool.
F. Crank the engine.
G. Compare the pressure reading on the gauge to the pressure

reading on the electronic service tool.
5. Replace the Fuel Filters Fuel filters Result: The problem has been resolved.
A. Replace the primary filter, the secondary filter, and the tertiary Return the engine to service.
fuel filters.
The fuel system will need to be primed after the filters are re- Result: The problem has not been resolved.
placed. Refer to Operation and Maintenance Manual for the
correct procedure. Proceed to Test Step 6.
B. Reset all active codes by cycling the keyswitch to the OFF posi-
tion for 2 minutes.
6. Check for Air in the Fuel System Air in the Result: Air is in the system.
system
A. Check for air in the fuel. Refer to Systems Operation/Testing and Repair: Refer to Systems Operation/Testing and Adjust-
Adjusting, “Air in Fuel - Test” for the correct procedure ing, “Air in Fuel - Test” for the correct repairs.
Result: Air is not in the system.
M0070030-01 273
(5) Anti-drain check valve (6) Fuel return pressure regulator
Table 174
7. Replace the Fuel Return Pressure Regulator Replace pres- Result: The problem has been resolved
sure regulator
A. Replace the fuel return pressure regulator. Return the engine to service.
B. Inspect the anti-drain check valve for proper operation. STOP
Result: The problem has not been resolved.
8. Replace the Transfer Pump Transfer pump Result: The transfer pump was replaced.
A. Replace the transfer pump. Reset all active codes and clear all logged codes by using
For information about testing the transfer pump, Refer to Testing the electronic service tool.
and Adjusting, “Fuel System Pressure - Test”.
Verify that the problem has been resolved.
STOP
Complete the procedure in the order in which the Note: Some of the following codes may not be
steps are listed. applicable for certain applications.
i06672376
Fuel System Water Separator

Has Water

codes:
274 M0070030-01
Table 175
J1939
Code PDL Code Code Description Comments
97–15 E232 (1) High Fuel/Water Separator A high level of water is detected in the water separators.
Water Level If equipped, the action lamp will illuminate.
97–16 E232 (2) High Fuel/Water Separator A high level of water is detected in the water separators.
Water Level The level in the water separator has been high for at least an hour. The operator
needs to empty the water separator.
The engine will be derated.
If equipped, the action lamp will illuminate.
Note: Visually identifying the presence of water in the

bowl may be impossible. Water may turn dark yellow
in the fuel system. Differentiating the water from the
fuel would then be difficult.
Troubleshooting Procedure
steps are listed.
M0070030-01 275
Table 176
1. Remove the Water from the Separator Bowl Water Result: The “Water in Fuel” warning disappeared.
A. Turn the ignition key to the OFF position. Allow the engine to run for 5 minutes.
B. Drain the fuel/water separator bowl. Refer to the Operation and Repair: If the “Water in Fuel” warning reappears, the fuel
Maintenance Manual, “Fuel System Primary Filter (Water Separa- supply is contaminated with water. Drain the fuel tank and
tor) - Drain”. then fill the fuel tank with clean fuel.
C. If necessary, prime the fuel system. Refer to the Operation and Return the unit to service.
Maintenance Manual, “Fuel System - Prime”.
Result: The “Water in Fuel” warning did not disappear.
D. Turn the ignition key to the ON position. Do not start the
E. Wait for 1 minute. The “Water in Fuel” warning should

disappear.
2. Check the Water Separator Switch for Correct Installation Sensor Result: There is a water separator switch installed.
Installed
A. Check the engine to determine if a water separator switch is Proceed to Test Step 3.
installed.
Result: There is no water separator switch installed.
Repair: Turn the keyswitch to the ON position. Connect the

electronic service tool and select “Configuration” . Select
“Engine Configuration Parameters” then disable the water
separator switch. Return to the unit service.
3. Check the Water Separator Switch and Harness Open or Result: The “Water Separator Has Water” warning
Short Circuit disappears.
Repair: Replace the water separator switch. Return the unit
B. Disconnect the harness. to service.
C. Create a short in the harness. Result: The “Water Separator Has Water” warning did not
disappear.
D. Turn the keyswitch to the ON position.
Repair: Repair the wiring or replace the wiring.
i06672470 • Fuel injector
Fuel Temperature Is High Use this procedure to troubleshoot high fuel

temperature. Use this procedure if one of the
following event codes is active. Refer to
The probable causes of high fuel temperature event codes. For information on the engine
monitoring system, refer to Troubleshooting, “Engine
• Associated codes Monitoring System”.
• Fuel level in the tank

• Fuel temperature sensor
• Fuel Cooler (if equipped)

• Fuel return pressure regulator
• Restriction in the fuel lines
276 M0070030-01
Table 177
Diagnostic Trouble Code

The fuel temperature is above an ac-
ceptable level.
174-15 E363 (1) Engine Fuel Temperature 1 High If equipped, the action lamp will
illuminate.
The code is logged.
174-16 E363 (2) Engine Fuel Temperature 1 High The fuel temperature is above an ac-
ceptable level.
If equipped, the action lamp will
E363 (3) Engine Fuel Temperature 1 High illuminate.
174-0
The code is logged.
There may be a decrease in power.
Table 178
Associated Codes
J1939 Code PDL Code
5580-17 E198 (1)
5580-18 E198 (2)
Table 179
1. Determine the Code Diagnostic trou- Result: An associated code is active or logged.
ble code
A. Check for active codes and check for logged codes on the elec- Repair: Troubleshoot any active codes before continu-
tronic service tool. ing with this procedure.
B. Check the electronic service tool for any associated codes that Result: An associated code is not active or logged.
are listed in Table 178 . Troubleshoot any active codes before con-
tinuing with this procedure. Proceed to Test Step 2.
2. Check the Fuel Level in the Fuel Tank Fuel level Result: The fuel level is acceptable.
A. Check the fuel level in the fuel tank. Proceed to Test Step 3.
Result: The fuel level is not acceptable.
Repair: Fill the tank. Verify that the problem has been
resolved. If the problem has not been resolved, proceed
to Test Step 3.
M0070030-01 277
Fuel return line
Fuel supply lines
278 M0070030-01
Table 180
3. Inspect the Fuel Supply Lines Dirt and debris or Result: The fuel lines and the cooler (if equipped) are
damage OK.
A. Visually inspect the fuel lines between the priming pump and
the inlet to the cylinder head. Also, inspect the fuel cooler for dirt, Proceed to Test Step 4.
debris, or damage, if equipped. Inspect the fuel return line from
the head to the fuel tank. Inspect the lines for restrictions, pinch- Result: The fuel lines and the cooler (if equipped) are
ing, and swelling. Refer to Systems Operation, Testing and Adjust- not OK.
ing, “Fuel System - Inspect” for additional information.
Repair: Replace damaged fuel lines and/or fuel cooler
B. Inspect the fuel cooler for dirt, debris, or damage, if equipped. (if equipped). Remove dirt or debris from fuel cooler fins
(if equipped). Verify that the problem has been resolved.
4. Replace the Temperature Sensor Active codes or Result: An E363 or 174 code is active or logged.
logged codes
A. Replace the fuel temperature sensor. Proceed to Test Step 5.
B. Check for active codes or logged codes. Result: An E363 or 174 code is not active or logged.
M0070030-01 279
(1) Fuel return pressure regulator
Table 181
5. Fuel Return Pressure Regulator Pressure Result: The problem has been resolved.
regulator
A. Replace the fuel return pressure regulator. Return the unit to service.
Result: The problem has not been resolved.
6. Perform a Cylinder Cutout Test Test was not Result: The Cylinder Cutout Test was not successful.
successful
A. Perform a “Cylinder Cutout Test” in the electronic service tool. Repair: Replace the identified injectors. Verify that all
trim files are installed into the ECM correctly. Refer to
Troubleshooting, “Injector Trim File - Install”. Repeat the
“Fuel System Verification Test” after making the neces-
sary repairs. Repeat the process until all the injectors
are operating properly.
i06672570
Idle Speed Is High

280 M0070030-01
Table 182
Description
J1939 Code PDL Code (Code descriptions may vary) Comments
The battery voltage is below 24.5 VDC for 5 minutes.
168-31 E441 (1) Battery Potential / Power Input #1 The engine speed is increased to 1000 rpm. The code
is logged.
Probable Causes
• Charging circuit
• Low battery engine elevated idle
Recommended Actions
steps are listed.
Table 183
1. Charging Circuit Charging Result: The charging circuit is operating properly.

Circuit
A. Inspect the battery and charging circuit. Refer to Systems Op- Proceed to Test Step 2.
eration, Testing and Adjusting, “Electrical System” for additional
information. Result: The charging circuit is not operating properly.
Repair: Repair the charging system. Verify the repair.
2. Low Battery Engine Elevated Idle Normal Result: This condition is normal operation.
Operation
A. This condition is normal operation. The engine idle speed will Return the unit to service.
be elevated to 1000 rpm when all the following conditions occur:
1. Low Battery Engine Elevated Idle is enabled.
2. A valid throttle position is present. The throttle position has not

exceeded 25 percent of full throttle for 5 minutes.
3. The transmission is in neutral.
4. The parking brake is engaged.
5. A valid engine speed is present.
6. System battery voltage is below 24.5 VDC for 5 minutes.
i06672604 • A system on the power train data links
Indicator Lamp Problem Recommended Actions

steps are listed.
Probable Causes
• Burned out bulb
• Problem with the lamp circuit
M0070030-01 281
Table 184
1. Check the Circuit for the Lamp Lamp Circuit Result: The electrical circuit is OK.
A. Check the electrical circuit for the lamp. Proceed to Test Step 2.
B. Refer to Troubleshooting, “Indicator Lamp - Test”. Result: The electrical circuit is not OK.
Repair: Repair the circuit. Verify the repair.
2. Check the Systems on the Power Train Data Link Power Train Result: A system that is connected to the power train da-
Data Link ta link is illuminating the lamp.
A. A system that is connected to the power train data link may be illu-
minating the lamp. Check the systems that are connected to the Repair: Troubleshoot the system causing the illumina-
power train data link. tion of the lamp.
B. Obtain the necessary equipment, when possible. Monitor the ap-

propriate parameters when the machine is experiencing problems.
Determine if the condition is normal operation.
i06674816
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. Refer to
event codes. Access the engine monitoring system
on the electronic service tool to view the current trip
points for these codes. For information on the engine
monitoring system, refer to Troubleshooting, “Engine
Monitoring System”.
Table 185
Description
J1939 Code PDL Code System Response
(Code descriptions may vary)
The air filter differential pressure is above the trip
107-15 E583 (1) High Air Inlet #1 Differential Pressure point pressure for the delay time.
The code is logged.
The air filter differential pressure is above the trip

point pressure for the delay time.
107-16 E583 (2) High Air Inlet #1 Differential Pressure
The code is logged.
The engine power is derated.
Table 186
J1939 Code PDL Code

107-3 582-3

steps are listed.
282 M0070030-01
Table 187
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.
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.
3. Check the Atmospheric Pressure Sensor, Turbocharger Damaged Sensors Result: The sensors and sensor circuits are OK.
Compressor Inlet Pressure Sensors, and/or Sensor Circuits
A. Use the electronic service tool to compare the value of the fol-
lowing parameters when the engine is off: Result: The sensors and sensor circuits are not OK.
1. “Atmospheric Pressure” Repair: Repair or replace the sensors and/or sensor

circuit. Verify that the problem is resolved.
2. “Turbocharger #1 Compressor Inlet Pressure (absolute)”
The value for air filter restriction is a calculated value. Before the
electronic service tool reports the status parameters for air filter re-
striction, the engine must be running for 3 minutes. The electronic
service tool will report “Conditions Not Met” for these parameters
prior to this delay time.
4. 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 problem is resolved.
i06674828
Intake Manifold Air Pressure Is

Low
Table 188 lists the diagnostic trouble code for low

intake manifold air pressure.

M0070030-01 283
Table 188
Code Description
Engine Intake Manifold #1 Pressure : The code is logged.

102-1 E1045 (3)
Low - most severe (3) Engine power is derated.
Engine Intake Manifold #1 Pressure : The code is logged.

102-18 E1045 (2)
Low - moderate severity (2) Engine power is derated.
Engine Charge Air Cooler Outlet The code is logged due to a restriction in the intake manifold
2630-1 E1107 (3)
Temperature : Low - most severe (3) that can be causes by icing.
Table 189
J1939 Code PDL Code

107-15 E583 (1)
107-16 E583 (2)

steps are listed.
Table 190
1. Check for Diagnostic Trouble Codes Codes Result: An associated code is active.
A. Connect to the electronic service tool. Repair: Refer to Troubleshooting, “Event Codes” to
troubleshoot the associated diagnostic code.
B. Determine if an associated code listed in Table 189 is active or
logged. Result: An associated code is not active or logged.
Result: An E1045 or 102-18 code is active.
2. Check the Air Inlet System for Restrictions Restrictions Result: The air filter is clean and a restriction is not
found.
A. Visually inspect the air filter for cleanliness on engines without
an electronic monitoring system on the inlet air system. A me- Proceed to Test Step 3.
chanical indicator may be used to monitor inlet air restrictions.
Use the indicator to determine the cleanliness of the inlet air sys- Result: The inlet air system is restricted.
tem. Also, inspect the piping for restrictions.
Repair: Clean the filter or replace the filter. Remove all
obstructions in the inlet air piping. Verify that the prob-
lem has been resolved. If the problem still exists, pro-
284 M0070030-01

Typical points of inspection
Table 191
3. Inspect the Air Piping and Connections Connections Result: The piping or hose connections were damaged.
A. Inspect the piping and the hose connections from the turbo- Repair: Replace the damaged piping or hose connec-
charger compressor outlet to the Air to Air Aftercooler (ATAAC) tions. Verify that the problem has been resolved.
inlet (if equipped). Remove the hose connections and inspect
the hose connections for cuts or damage. If the problem still exists, proceed to Test Step 4.
Result: The piping was not damaged.
4. Perform an ARD Air System Service Test ARD Air Service Result: The ARD Air System Service Test did not com-
Test plete successfully.
A. Perform the “ARD Air System Service Test” in the electronic
service tool. The test will verify that the ARD air valve is working Repair: Replace the ARD air valve. Verify that the prob-
properly. lem has been resolved. Perform the ARD Air System
Service Test.
Return the engine to service if the test was successful.

If the test was not successful, proceed to Test Step 5.
Result: The ARD Air System Service Test did complete

successfully.
5. Inspect the Turbocharger Turbocharger Result: The turbocharger wheels are damaged.
A. Remove the connection for the inlet air and the exhaust con- Repair: Replace the turbocharger. Return the unit to
nection to the turbocharger. Verify that the compressor wheel service.
and the turbine wheel are spinning freely. Verify that the com-
pressor wheel and the turbine wheel are not damaged.
M0070030-01 285
i06674830
Intake Manifold Air

Temperature Is High
Table 192 lists the diagnostic trouble codes for high

intake manifold air temperature.

Table 192
Code Description
J1939 PDL (code descriptions may Comments
Code Code vary)
The code indicates that the temperature of the intake air into the engine has risen above
High Intake Manifold Air a predetermined threshold. The value is obtained from a virtual sensor. For information
105-0 E539 (3)
Temperature on virtual sensors, refer to System Operations, Testing and Adjusting.
Engine power may be derated.
105-15 E539 (1)
105-16 E539 (2)
Table 193
J1939 Code PDL Code

412-15 E1092 (1)
412-16 E1092 (2)

steps are listed.
286 M0070030-01
Table 194
1. Check for Diagnostic Trouble Codes Codes Result: An associated code is active.
A. Establish communication between the electronic service tool Repair: Refer to Troubleshooting, “Event Codes” to trou-
and the Electronic Control Module (ECM) . Refer to Troubleshoot- bleshoot the associated diagnostic code.
Result: An associated code is not active or logged.
B. Determine if an associated code is active or logged. Table 193
lists associated diagnostic codes. Proceed to Test Step 2.
Result: An E539 or 105 diagnostic code is active.

Inspection point
M0070030-01 287
Table 195
2. Check the Aftercooler for Leaks or Restrictions Restrictions Result: The ATAAC has an excessive buildup of dirt or
debris.
A. Inspect the exterior surface of the ATAAC for excessive buildup
of dirt or debris. Also verify that the fins of the ATAAC are not Repair: Clean the ATAAC. Refer to the machine Test and
damaged. Adjust manual. Verify that the problem has been
resolved.
If the problem still exists, proceed to Test Step 3.
Result: The surface of the ATAAC is damaged.
Repair: Replace the ATAAC.
Result: The surface of the ATAAC is not damaged and

the ATAAC does not have an excessive buildup of dirt or
debris.
3. Check the Operation of the Cooling Fan Cooling Fan Result: The fan drive system is not working properly.
A. Verify that the cooling fan that is being used to transfer heat Repair: Make the necessary adjustments to the clutch or
from the ATAAC is working properly. the belt tension if the fan is mechanically driven . Refer to
Systems Operation, Testing and Adjusting for the proper
B. If the fan is belt driven, verify that the belt tension is adequate. procedure. Repair leaks or make the necessary adjust-
Also, verify that the clutch is operating properly. ments to the motor or the hydraulic pump if the fan is hy-
draulically driven . Refer to Systems Operation, Testing
C. If the fan is hydraulically driven, verify that there is no leakage and Adjusting for the proper procedure.
around the motor and that the pressure for the fan is adequate.
Result: The fan drive system is working properly.
4. Check the Operation of the Charge Air Cooler Outlet Tem- Sensor Result: The value of the charge air cooler outlet tempera-
perature Sensor ture sensor is within ± −9° C (±15° F) of the ambient
temperature.
A. Remove the charge air cooler outlet temperature sensor. Allow
the charge air cooler outlet temperature sensor to rest in ambient Repair: Reinstall the sensor. Torque the sensor to the
air for 2 minutes. proper specifications. Return the unit to service.
B. Connect to the engine ECM by using the electronic service Result: The value of the charge air cooler outlet tempera-
tool. ture sensor is not within ± −9° C (±15° F) of the ambient
temperature.
C. Monitor the value of the charge air cooler outlet temperature
sensor on the electronic service tool. Repair: Replace the charge air cooler outlet temperature
sensor. Return the unit to service.
288 M0070030-01
i06917780
NOx Conversion Is Low
Table 196
Code Description
J1939 (code descriptions may
PDL Code Comments
Code vary)
3516-16 E1365 (2) Aftertreatment 1 Diesel Exhaust The Diesel Exhaust Fluid (DEF) has a high concentration.
Fluid Concentration : High -
3516-18 E1364 (2) Aftertreatment 1 Diesel Exhaust The Diesel Exhaust Fluid (DEF) has a low concentration.
Fluid Concentration : Low - mod-
erate severity (2)
Aftertreatment #1 SCR Catalyst

The Engine Out and Tailpipe Out NOx Sensors are installed in the incorrect
4364-2 E1410 (2) Conversion Efficiency : Erratic,
locations.

4364-18 E1309 (2) Conversion Efficiency : Low - The SCR System is not able to reduce NOx in the exhaust system.
Table 197
Required Service Tools
T400236 Kit - Test

steps are listed.
M0070030-01 289
Table 198
1. Determine the Diagnostic Code Diagnostic Code Result : An E1410 (2) or 4364-2 code is active or
logged.
and the Electronic Control Module (ECM). Refer to Trouble- Proceed to Test Step 2.
shooting, “Electronic Service Tools”, if necessary.
Result : For all codes other than a E1410 (2) or 4364-
B. Determine the diagnostic trouble code that is active. 2, proceed to Test Step 3.
2. Check the NOx sensors for Correct Installation NOx Sensors Result : The “Aftertreatment System Functional Test”
completed successfully.
B. Verify that the sensors are located in the correct position.
Note : The “Engine Out NOx” sensor wiring has a black sheath. Result : The “Aftertreatment System Functional Test”
The “Tailpipe Out NOx” sensor wiring has a gray sheath. did not complete successfully and other codes were
logged.
C. If the sensors are installed in the wrong positions, install the
sensors in the correct positions. Refer to Disassembly and As- Repair : Troubleshoot the logged codes. Refer to Trou-
sembly, Nitrogen Oxide Sensor - Remove and Install for the cor- bleshooting for the code that became active during the
rect handling procedures. test.
D. Perform an “Aftertreatment System Functional Test” using

3. Check the Diesel Exhaust Fluid (DEF) Quality. DEF Result : The DEF is not contaminated and the concen-
tration is not within the acceptable range.
A. Measure the DEF quality. Refer to Systems Operation, Test-
ing and Adjusting, “Diesel Exhaust Fluid Quality - Test” for the Repair : Drain the DEF from the tank. Refill the tank
correct procedure. with DEF that meets ISO 22241 quality standards.
Result: The DEF not contaminated and the concentra-

tion is within the acceptable range.
Repair : Contact the DSN for further information.
4. Determine the DEF Quality Sensor Installation Status Parameter Result : “Aftertreatment #1 DEF Quality Sensor Instal-
lation Status” is set to “Installed” .
A. Use Cat ET to check the status of the configuration parame-
ter “Aftertreatment #1 DEF Quality Sensor Installation Status” . Proceed to Test Step 5.
Result : “Aftertreatment #1 DEF Quality Sensor Instal-

lation Status” is set to “Not Installed” or is not listed.
(continued)
290 M0070030-01
(Table 198, contd)

5. Determine the Diagnostic Code Code Result : An E1365 (2), 3516–16, E1364 (2), or 3516–
18 code is active or logged.
A. Connect Cat ET
Repair : Replace the DEF tank header assembly.
B. Determine the code that is active.
Result : An E1309 (2) or 4364–18 code is active or

logged.
6. Inspect all the DEF lines for Leaks DEF Lines 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. Connect to the “Diesel Exhaust Fluid Controller #1 ECM” in Proceed to Test Step 14.
Result : The lines are not leaking, damaged, pinched,
C. Perform the “DEF Dosing System Verification Test” to pres- or disconnected.
surize the system. Refer to Troubleshooting, “Service Tool Fea-
tures” for more information. Proceed to Test Step 6.
D. Visually inspect all DEF lines from the tank to the DEF injec-
tor. Look for pinched, damaged, or disconnected lines.
E. Inspect the lines for leakage.
7. Perform an “ Aftertreatment NOx Sensor Functional Test”” Aftertreatment NOx Result : The test completed successfully.
. Sensor Functional
Test Proceed to Test Step 8.
Result : The test did not complete successfully. A failed
B. Connect to the “Engine #1 Aftertreatment Control ECM” us- NOx sensor was detected.
Repair : Replace the failed NOx sensor. Refer to Disas-
C. Perform an “Aftertreatment NOx Sensor Functional Test” . sembly and Assembly, Nitrogen Oxide Sensor - Re-
move and Install for the correct handling procedures.
(continued)
M0070030-01 291
(Table 198, contd)

8. Perform a “ DEF Dosing System Accuracy Test”” . DEF Dosing System Result : The quantity collected is within specifications.
Accuracy Test
A. Perform a “DEF Dosing System Accuracy Test” using the Repair : Re-Install the DEF injector. Refer to Disas-
electronic service tool. Refer to Systems Operation, Testing and sembly and Assembly for the correct procedure.
Adjusting, “Aftertreatment SCR System Dosing Test” for the
correct procedure. Proceed to Test Step 12.
Result: The quantity collected is below specifications.

Result : The quantity collected is above specifications.
A failed DEF injector has been detected.
Repair : Replace the DEF injector. Refer to Disassem-
bly and Assembly for the correct procedure.
9. Check the DEF Pressure Line DEF Pressure Line Result : An obstruction was found.
A. Turn the keyswitch to the OFF position. Allow 2 minutes to Repair : Flush the line or replace the line.
elapse before proceeding. Proceed to Test Step 11.
B.. Remove the DEF pressure line between the DEF pump and Result : There are no obstructions.
the DEF injector. Refer to the Disassembly and Assembly man-
ual for the correct procedure. Repair : Reinstall the line.
C. Inspect the line for obstructions. Flush the line with water or Proceed to Test Step 10.
low-pressure air, if necessary. Possible obstructions are ice,
DEF deposits, or debris.
10. Replace the DEF Injector DEF Injector Result: The DEF injector was connected to the DEF
pressure line and the electrical connector.
B. Replace the DEF injector. Refer to the Disassembly and As-
sembly manual for the correct procedure for replacing the DEF
injector.
Note : Do not install the injector until Step 11 has been

completed.
11. Perform a “ DEF Dosing System Accuracy Test”” . DEF Dosing System Result : The quantity collected is within specifications.
Accuracy Test
A. Perform a “DEF Dosing System Accuracy Test” using the Repair : Install the DEF injector.
electronic service tool. Refer to Systems Operation, Testing and
Adjusting, “Aftertreatment SCR System Dosing Test” for the Proceed to Test Step 14.
correct procedure.
Result : The quantity collected is below specifications.
Repair : Replace the DEF pump. Install the DEF

injector.
(continued)
292 M0070030-01
(Table 198, contd)

12. Check for Exhaust Leaks Exhaust Leaks Result : There were exhaust leaks found.
Repair : Repair or replace the component that is caus-
B. Check the exhaust system for leaks or damage. ing an exhaust leak.
C. Check all exhaust connections from the turbo outlet to the Proceed to Test Step 14.
tailpipe outlet.
Result : There were no exhaust leaks found.
D. Check for damage to the exhaust system insulation.
13. Determine the Fuel Quality Fuel Quality Result : The fuel quality is OK.
A. Take a fuel sample from the fuel tank. Refer to Systems Op- Proceed to Test Step 14.
eration, Testing and Adjusting, Fuel Quality - Test.
Result : The fuel quality is NOT OK.
Repair : Inform the owner of the equipment that Ultra

Low Sulfur Diesel fuel must be used in order for the en-
gine to operate properly.
Drain the fuel tank and replace the fuel with fuel that
meets the specifications for the engine. Proceed to Test
Step 14.
14. Perform an “ Aftertreatment System Functional Test”” Aftertreatment Sys- Result : The test completed successfully.
tem Functional Test
B. Connect to the “Engine #1 Aftertreatment Control ECM” us- Result : The test did not complete successfully.
C. Perform an “Aftertreatment System Functional Test” .
15. 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. Refer to Disassembly and As- Proceed to Test Step 16.
sembly, Nitrogen Oxide Sensor - Remove and Install for the cor-
rect handling instructions.
D. Perform an “Aftertreatment System Functional Test” .
(continued)
M0070030-01 293
(Table 198, contd)

16. Check the exhaust mixer for damage. Exhaust Mixer Result : The exhaust mixer was not damaged.
A. Turn the keyswitch to the OFF position. Proceed to Test Step 17.
B. Allow the CEM sufficient time to cool down. Result : The exhaust mixer was damaged.
C. Remove the mixing tube between the DPF outlet and SCR Repair : Replace the exhaust mixing tube. Remove
inlet. Refer to Disassembly and Assembly for the correct any debris from the SCR inlet. Refer to Disassembly
procedure. and Assembly for the correct procedure.
D. Inspect the exhaust mixer for damage. Proceed to Test Step 18.
17. Replace the SCR Catalyst SCR Catalyst Result : The SCR catalyst was replaced.
A. Replace the SCR catalyst. Refer to Disassembly and As- Proceed to Test Step 18.
sembly for the correct procedure.
B. Refer to Troubleshooting, Service Tool Features, Aftertreat-

ment SCR Catalyst Replacement for the SCR reset procedure.
18. Perform an “ Aftertreatment System Functional Test”” Aftertreatment Sys- Result : The test completed successfully.
tem Functional Test
B. Connect to the “Engine #1 Aftertreatment Control ECM” us-

i06675858
NRS Exhaust Gas Temperature

Is High

trouble codes:
Note: The following codes may not be applicable for


Table 199
Code Description
The temperature of the NRS exhaust gas has exceeded the
412-15 E1092 (1) High EGR Temperature
threshold for a set amount of time.
The temperature of the NRS exhaust gas has exceeded the
412-16 E1092 (2) High EGR Temperature
threshold for a set amount of time.
294 M0070030-01

Typical left side engine view
(1) NRS inlet valve (2) NRS temperature sensor (3) NRS outlet valve
Table 200
J1939 Code PDL Code

110-15 E361 (1)
110-16 E361 (2)
110-0 E361 (3)

steps are listed.
M0070030-01 295
Table 201
1. Check for Associated Diagnostic Trouble Codes Associated Result: There are associated codes.
Code
A. Establish communication between the electronic service tool Repair: Refer to Troubleshooting, “Diagnostic Trouble
and the Electronic Control Module (ECM) . Refer to Troubleshoot- Codes” to troubleshoot the associated diagnostic code.
Result: An E1092 or 412 code and an E1095 or 2659
B. Determine if an associated code is active or logged. Table 200 code are present.
lists associated diagnostic codes.
Result: There are no associated codes.

NRS cooler
(4) Exhaust outlet (6) Exhaust inlet (8) Coolant outlet
(5) Vent port (7) Coolant inlet
296 M0070030-01
Table 202
2. Perform a “ EGR System Test”” Test Completed Result: The “EGR System Test” did not complete due to
Successfully a E1092 (2) or 412-16 code.
A. Reset all active codes and clear all logged codes. Use the elec-
tronic service tool to perform an “EGR System Test” to verify that Repair: Repair the vent line or replace the vent line from
the problem is resolved. the cooler to the shunt tank. Remove the exhaust lines
from the inlet and the outlet of the cooler. Inspect the in-
ternal passage of the cooler for coolant. If coolant is
found, replace the cooler.
Repair: Reset all active codes and clear all logged co-
des. Use the electronic service tool to perform an “EGR
System Test” to verify that the problem is resolved.
Result: The “EGR System Test” completed successfully.

Typical right side engine view
(9) NRS cooler
M0070030-01 297
Table 203
3. Inspect the NRS Cooler Leakage Result: The cooler has internal leakage.
A. Remove the NRS cooler. Refer to Disassembly and Assembly, Repair: Replace the cooler. Replace the connection for the
Exhaust Cooler (NRS) - Remove and Install for the correct bellows at the inlet of the cooler.
procedure.
Reset all active codes and clear all logged codes. Use the
B. Perform a leak test on the cooler. Refer to System Operation, electronic service tool to perform an “EGR System Test” to
Testing and Adjusting, “Exhaust Cooler (NRS) - Test” for the proper verify that the problem is resolved.
procedure.
Result: The cooler did not have internal leakage.
Repair: Clean the cooler. Refer to Testing and Adjusting, “Ex-

haust Cooler (NRS) - Clean” for the correct procedure to clean
the cooler for the NRS.
i06260326
Oil Consumption Is Excessive
Probable Causes
• Incorrect oil level in the crankcase
• Oil leaks on the outside of the engine

• Oil leaks in the combustion area of the cylinders
• Oil leakage at the injector

• Incorrect oil viscosity
• Condition of turbocharger
Recommended Actions
298 M0070030-01
Table 204
1. Excessive Oil in the Crankcase Oil level Result: The oil level is correct.
A. Check the engine oil level. Too much oil in the engine crankcase Proceed to Test Step 2.
can cause the engine to consume oil.
Result: The oil level is high.
B. Ensure that the dipstick is properly calibrated and/or that the dip-
stick is correct for the application. Calibrate the dipstick and/or re- Repair: Remove excessive engine oil from the
place the dipstick. Refer to Systems Operation/Testing and crankcase.
Adjusting, “Lubrication System” for calibration of the dipstick gauge. Verify the repair.
2. Oil Leaks on the Outside of the Engine Oil leaks Result: There are oil leaks on the outside of the engine.
A. Check for oil leaks on the outside of the engine. Refer to Sys- Repair: Find the source of the oil leaks and make the
tems Operation/Testing and Adjusting, “Lubrication System”. necessary repairs.
Result: There are no oil leaks on the outside of the

engine.
3. Oil Leaks in the Combustion Area of the Cylinder Oil leaks Result: There are oil leaks in the combustion area of the
cylinder.
A. Check for oil leaks in the combustion area of the cylinders.
Repair: Make the necessary repairs. Replace parts, if
B. Check for excessive engine blowby. Excessive engine blowby necessary.
will cause unnecessary oil consumption. Excessive engine blowby
can also cause unnecessary engine wear. Result: There are no oil leaks in the combustion area of
the cylinder.
4. Oil Leakage At the Injector Oil leakage Result: There is oil leakage at the injector.
A. Check for the excessive transfer of oil from the high-pressure oil Repair: Make the necessary repairs. Replace parts, if
supply in the injector to the fuel return in the cylinder head. necessary.
There is not oil leakage at the injector.
5. Oil Viscosity Viscosity Result: The engine oil viscosity is correct.
A. Excessive consumption of engine oil can also result if engine oil Proceed to Test Step 6.
with the wrong viscosity is used. Engine oil with a thin viscosity can
be caused by fuel leakage into the crankcase or by increased en- Result: The engine oil viscosity is not correct.
gine temperature. Refer to the Operation and Maintenance Manual
for additional information. Repair: Replace the engine oil, Refer to the Operation
and Maintenance Manual for additional information.
6. Condition of Turbocharger Turbocharger Result: The turbocharger has leakage.
A. Check the turbocharger for leakage. Repair: Make the necessary repairs. Replace parts, if
necessary.
M0070030-01 299

steps are listed.
i06260330
Oil Contains Coolant
Emulsion is a mixture of oil and water. The water

occurs when condensation forms in the engine during
certain operating and seasonal conditions. The
emulsion may appear light in color. Emulsion may be
found in the following areas:
• Engine oil filler
• Engine oil level gauge

• Valve cover
• Crankcase ventilation system

The emulsion should disappear with increased
engine operating temperatures at higher load
conditions.
Probable Causes
• Leaks in the core of oil cooler
• Leaks in the core of the NRS cooler
• Cracks in the turbocharger housing or center

section
• Leaks in the cylinder head gasket
• Damaged water seals

• Cracks in the cylinder head
• Cracks in a cylinder liner

• Liner seals
• Cracks in the cylinder block
300 M0070030-01
Recommended Actions
Table 205
1. Leaks in Core of Oil Cooler Oil cooler Result: The oil cooler is leaking.
A. Check for leaks in the oil cooler core. Repair: Repair or replace the oil cooler.
Result: The oil cooler is not leaking.
2. Exhaust (NRS) Cooler NRS cooler Result: The exhaust (NRS) cooler is leaking.
A. Check the NRS cooler for leaks. Refer to Testing and Adjust- Repair: Repair or replace the exhaust (NRS) cooler.
ing, “Exhaust Cooler (NRS) - Test”.
Result: The exhaust (NRS) cooler is not leaking.
3. Liquid Cooled Turbochargers Turbocharger Result The turbocharger housing or center section has
cracks.
A. Inspect the turbocharger housing and center section for
cracks. Repair: Make any repairs, as required.
Result The turbocharger housing or center section does not

have cracks.
4. Leaks in the Cylinder Head Gasket Head gasket Result The cylinder head gasket is leaking.
A. Inspect the cylinder head gasket for leaks. Repair: Replace the cylinder head gasket.
Result The cylinder head gasket is not leaking.
5. Damaged Water Seals Water seals Result The water seal is damaged.
A. Inspect the water seal for damage. Repair: Repair or replace the damaged seal.
Result The water seal is not damaged.
(continued)
M0070030-01 301
(Table 205, contd)

6. Cracks in the Cylinder Head Cylinder head Result The cylinder head is damaged.
A. Check for cracks in the cylinder head. Repair: Repair or replace the damaged cylinder head.
Result The cylinder head is not damaged.
7. Cracks in a Cylinder Liner Cylinder liner Result The cylinder liner or seal is damaged or cracked.
and seals
A. Check for cracked cylinder liners. Repair: Repair or replace the damaged cylinder liner and
seal.
B. Check the liner seals for damage.
Result The cylinder liner or seal is not damaged or cracked.
8. Cracks in the Cylinder Block Cylinder liner Result The cylinder block is cracked.
A. Inspect the cylinder block for cracks. Repair: Repair or replace the damaged cylinder block.
9. Pressurize the Cooling System Leaks Result: The test indicates a drop in pressure.
A. Pressurize the cooling system. Refer to Systems Operation/ The leak still exists.
Testing and Adjusting, “Cooling System - Test”.
Repair: Make any repairs, as required.
Result: The test indicates that there is not a drop in

pressure.
Result: The engine oil was changed.

10. Change the Engine Oil Oil
A. Drain the engine oil.
B. Refill the engine with clean oil.
C. Run the engine until the engine is at normal operating

temperature.
D. Drain the engine oil, replace the oil filters, and refill the en-
gine with clean oil.
302 M0070030-01
Complete the procedure in the order in which the Table 206

steps are listed. Oil Test Kits
i06260337 Region Part Number
North America and South 29990014

Oil Contains Fuel America
Rest of the world 29990011
Measuring Fuel Dilution 2. Follow the instructions that are supplied with the oil
test kit.
Diesel fuel is chemically similar to the lubricants that
are used in diesel engines. A slow fuel leak will blend 3. Obtain a sample of the oil from the engine. Refer to
the fuel into the oil. Normal operating temperatures Operation and Maintenance Manual, “Fluid
may cause volatile parts of the fuel to vaporize. The Recommendations - Engine Oil”.
fuel that remains in the oil is less volatile.
4. Complete the form that is included with the oil test
A closed cup flash test can be performed in order to
detect fuel dilution. The flash test is designed to kit.
measure the volatile parts of the fuel that are 5. Send the oil sample for analysis. Follow the
remaining in the oil. Detecting less volatile fuel is instructions that are included with the oil test kit.
difficult. The less volatile fuel reduces the accuracy of
the flash test.
Probable Causes
Since the flash test does not accurately detect
fuel dilution, do not use the flash test as the only • Leaking seals
measure of fuel dilution. Instead, verify the dilution
by the following methods: • Fuel injector tip
• Gas chromatograph fuel dilution test • Fuel transfer pump seal
• Oil viscosity • Cracked cylinder head
The test that uses a gas chromatograph is designed Recommended Actions

to measure fuel dilution in crankcase oils. The gas
chromatograph can identify the small chemical Note: The procedures have been listed in order of
differences between diesel fuel and lubricating oil. probability. Complete the procedures in order.
Even though the gas chromatograph provides a more
accurate measure of fuel dilution, always verify the
results with the viscosity test.
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.
Fuel dilution that is greater than 10 percent will
usually cause viscosity that is less than the specified
viscosity grade. If the oil is still within the specified
viscosity grade, fuel dilution has not reached an
unacceptable level.
Verifying Fuel Dilution

Always verify fuel dilution by the combination of a
viscosity test and a gas chromatograph test. If the
result is in excess of 10 percent, investigate the
cause.
1. Obtain an oil test kit. Refer to table
M0070030-01 303
Table 207
1. Leaking Seals O-ring seal Result: The injector O-ring seal is damaged.
A. Remove the injector from the affected cylinder and visually in- Repair: Replace the damaged seals. Install the injector onto
spect the injector O-ring seals for damage. the engine and confirm that the repair has resolved the
problem.
If leakage is found and the O-rings are in good repair, there may
be a problem with the injector. Replace the injector. Ensure that Result: The injector O-ring seal is not damaged.
the new trim files are installed. Refer to Troubleshooting, “Injector
Trim File - Install” for details. Use the electronic service tool to per- Proceed to Test Step 2.
form a “Fuel System Verification Test” . Refer to Troubleshooting,
“Injector Solenoid - Test” for details.
If the leakage is not located, add the appropriate dye to the fuel
tanks. Run the engine at high idle for several minutes. Shut down
the engine and remove the valve covers. Use a black light to
check for traces of dye around each injector.
2. Fuel Injector Tip Injector tip Result: The fuel injector tip is damaged.
A. Use the electronic service tool to perform the “Cylinder Cutout Repair: Replace the suspect injector.
Test” in order to identify any cylinders that may be overfueled.
Result: The fuel injector tip is not damaged.
B. A fuel injector tip that is broken or fractured is a possible cause
of a cylinder that is being overfueled. If a cylinder is identified by Proceed to Test Step 3.
the test, Remove the injector and check the injector tip for dam-
age. Check the fuel injector tip for cracks or breakage.
3. Fuel Transfer Pump Seal Pump seal Result: There is fuel leakage around the shaft seal.
A. Check for fuel leakage around the shaft seal for the fuel transfer Repair: Replace the fuel transfer pump.
pump. Ensure that the weep hole is not plugged.
Result There is not fuel leakage around the shaft seal.
4. Cracked Cylinder Head Cracked Result The internal passages for the fuel supply to the injec-
head tors are damaged.
A. Look for signs of damage to the internal passages for the fuel
supply to the injectors in the cylinder head. Check for pin hole Repair: Repair or replace the cylinder head.
leaks. Refer to Disassembly and Assembly.
Complete the procedure in the order in which the Use this procedure to troubleshoot low engine oil
steps are listed. pressure. Use this procedure if one of the following
event codes is active. Refer to Troubleshooting,
i06675910 “Event Codes” for information about event codes and
the default trip points for these codes. For information
on the engine monitoring system, refer to
Oil Pressure Is Low Troubleshooting, “Engine Monitoring System”.
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 Operation and
Maintenance Manual for details.
304 M0070030-01
Table 208
Code Description
Oil pressure is lower than the specified pressure for at least 4 seconds. Engine
power is reduced. A snapshot is triggered. The code is logged. Factory pass-
100-1 E360 (3) Low Engine Oil Pressure words are required.
After 30 seconds, the ECM will shut down the engine if the “Engine Monitoring
Mode” parameter is programmed to “Shut down” .
Oil pressure is below the specified pressure for at least 8 seconds. A snapshot is
100-17 E360 (1) Low Engine Oil Pressure
triggered. The code is logged. Engine performance is not affected.
Oil pressure is lower than the specified pressure for at least 4 seconds. Engine
power is reduced. A snapshot is triggered. The code is logged. Factory pass-
100-18 E360 (2) Low Engine Oil Pressure words are required.
After 30 seconds, the Engine Control Module (ECM) will shut down the engine if
the “Engine Monitoring Mode” parameter is programmed to “Shut down” .
Probable Causes
• Low engine oil level
• Aeration in the oil

• Low oil viscosity
• Plugged Oil Filter

• Faulty oil pump
• Faulty engine oil pressure sensor

• Faulty bypass valve
• Damaged suction tube or cracked suction tube

• Excessive wear of engine components
Recommended Actions
steps are listed.
Table 209
1. Engine Oil Level Oil Result: The engine oil level is low.
A. Check the engine oil level in the crankcase. Refer to the Opera- Repair: Add engine oil to obtain the correct engine oil level.
tion and Maintenance Manual for calibration of the dipstick gauge. Refer to Operation and Maintenance Manual, “Engine Oil” for
The oil level can possibly be too far below the oil pump supply the recommendations of engine oil.
tube. The oil pump cannot supply enough lubrication to the engine
components. Start the engine. Inspect the exterior of the engine for oil
leaks. Repair any oil leaks.
Result: The engine oil is not low.
(continued)
M0070030-01 305
(Table 209, contd)
2. Aerated Oil Aeration Result: The oil is aerated.
A. Sample the engine oil for aeration. Proceed to Test Step 8.
Foamy oil on the dipstick is a good indication of aeration. Result: The oil is not aerated.
3. Oil Viscosity Oil Viscosity Result: The oil viscosity is not correct.
A. Sample the engine oil viscosity. Repair: Replace the engine oil.
B. Access the “Cylinder Cutout Test” in the “Diagnostic Tests” Refer to Operation and Maintenance Manual, “Engine Oil” for
under the “Diagnostics” menu. the recommendations of engine oil. If the symptom is cor-
rected, return the unit to service. If the symptom still exists,
C. Perform the “Automatic Cylinder Cutout Test” on the electronic proceed to Test Step 4.
service tool.
Result: The oil viscosity is correct.
4. Oil Filter Filter Result: The oil filter was changed.
A. Replace the engine oil filter. If the symptom is corrected, return the unit to service.
If the symptom still exists, proceed to Test Step 5.
5. Oil Pump Oil Pressure Result: The oil pressure is meets specifications.
A. Manually check the engine oil pressure. Refer to Systems Oper- Proceed to Test Step 6.
ation, Testing and Adjusting, “Engine Oil Pressure - Test” for the
correct procedure. Result: The oil pressure does not meet specifications.
Repair: Replace the oil pump. If the symptom is corrected,

return the unit to service.
306 M0070030-01

(1) Oil pressure sensor

(2) T Fitting
M0070030-01 307
Table 210
6. Engine Oil Pressure Sensor Sensor Result The pressure is within ± 34 kPa (± 5 psi).
A. Remove the connector and the oil pressure sensor. Proceed to Test Step 7.
B. Install an appropriate “T” fitting in the pressure sensor Result The pressure is not within ± 34 kPa (± 5 psi).
port.
Repair: Replace the sensor. If the symptom is cor-
C. Install a manual gauge on one side of the “T” fitting. In- rected, return the unit to service.
stall the oil pressure sensor on the other side of the pipe “T”
fitting. If the symptom still exists, proceed to Test Step 7.
D. Start the engine and compare the oil pressure between

the manual gauge and the electronic service tool. The pres-
sure reading must be within ± 34 kPa (± 5 psi).
7. Engine Oil Filter Bypass Filter Base Result: The oil filter base was replaced.
A. Replace the oil filter base. If the symptom is corrected, return the unit to service.
8. Oil Pump Suction Tube Suction Tube Result: The suction tube and seal are OK.
A. Remove the oil pan. Proceed to Test Step 9.
B. Inspect the suction tube. Check the joints of the tube for Result: The suction tube and seal are not OK.
cracks or for a damaged O-ring seal at the connection to the
pump. Repair: Replace any damaged parts.
C. Inspect the inlet screen of the suction tube for a restric-

tion. This restriction will cause cavitation and a loss of en-
gine oil pressure.
9. Worn Engine Components Worn Parts Result: There are worn engine components.
A. Remove the valve covers. Repair: Replace parts, if necessary. Check the Reuse
and Salvage Guidelines for the reusability of existing
B. Inspect the camshaft and bearings. engine components.
C. Remove the oil pan.
D. Excessive clearance at the crankshaft or camshaft bear-

ings will cause low engine oil pressure. Check the engine
components for excessive clearance. Also, inspect the pis-
ton cooling jets.
i06675952
Oil Temperature Is High
Use this procedure to troubleshoot high oil

temperature or use this procedure if one of the
following event codes is active.
308 M0070030-01
Table 211
Code Description
J1939 Code PDL Code (code descriptions may Comments
vary)
175-15 High Engine Oil Temperature - The code is logged.
E197 (1)
Least Severe (1)
175-16 E197 (2) High Engine Oil Temperature - The code is logged.
Moderate Severity (2) Engine power is derated.
175-0 E197 (3) High Engine Oil Temperature - The code is logged.
Most Severe (3) The engine is shut down.
If the engine is shut down due to a high engine oil

temperature, the power to the engine Electronic
Control Module (ECM) must be cycled to restart the
engine.
Table 212
Associated Codes
J1939 Code PDL Code
175-3 N/A
175-4 N/A
110-0 E361(3)
110-15 E361(1)
110-16 E361(2)
Probable Causes
• Diagnostic codes and event codes
• Coolant temperature is high

• Oil level is low
• Oil cooler bypass valve
• Oil cooler core problem
Recommended Actions
probability. Complete the procedures in the order of
the listed test steps.
M0070030-01 309
Table 213
1. Check for Associated Diagnostic Trouble Codes Associated Result: An associated code is present.
Code
A. Connect the electronic service tool to the service tool connec- Repair: Troubleshoot any associated codes before continu-
tor. Refer to Troubleshooting, “Electronic Service Tools”, if ing with this procedure.
necessary.
Result: A 175-0, 175-15, 175-16 or E197 code is present.
B. Determine if an associated diagnostic code is present.
Proceed to Step 2.
2. Check the Engine Oil Level Level Result: The engine oil level is OK.
Proceed to Step 3.
Result: The level is NOT OK.
Repair: Add oil and repair any leaks.
If the problem is not resolved, Proceed to Step 3.
3. Check the Engine Oil Cooler Bypass Valve Valve Result: The valve is OK.
A. Ensure that the bypass valve is not stuck in the open position. Proceed to the next step.
Clean the bore for the valve.
Inspect the components of the engine oil cooler bypass valve for Result: The valve is NOT OK.
damage.
Repair: Free the valve or replace the valve.
If the problem is not resolved, Proceed to Step 4.
4. Check the Engine Oil Cooler Core Cooler Result: The cooler core is NOT OK.
Check the engine oil cooler core for damage and for plugging. Repair: Clean the engine oil cooler core or replace the en-
Clean the engine oil cooler core or replace the engine oil cooler gine oil cooler core, if necessary.
core, if necessary.
i06676048 • Fuel system components
Power Is Intermittently Low or • Fuel supply pressure
Power Cutout Is Intermittent • Restriction in the air inlet and exhaust system
• Excessive temperatures of the turbocharger that
cause engine derates
Note: Use this procedure only if the engine does not
shut down completely. Recommended Actions
Note: Refer to Troubleshooting, “Service Tool Complete the procedure in the order in which the
Features” for information about service features. steps are listed.
Probable Causes
• Check for diagnostic trouble codes
• Electrical connections not properly connected.
• Intermittent throttle signal
310 M0070030-01
Table 214
1. Diagnostic Codes Diagnostic Result: A diagnostic code is active or logged.

Codes
A. Certain codes may derate engine power. Connect the electronic Repair: Troubleshoot any codes that are present before
service tool and check for active codes and/or for logged codes. continuing with this procedure.
Result: A diagnostic code is not active or logged.
2. Electrical Connections Electrical Result: The connectors are installed correctly.

Connectors
A. Verify that the following connectors are installed correctly: Proceed to Test Step 3.
1. Electrical connectors for the ECM Result: The connectors are not installed correctly.
2. Connectors for the wiring harness under the valve cover Repair: Install the connectors correctly. Refer toTrouble-
shooting, “Electrical Connectors - Inspect” for the proper
3. Connectors for the engine speed/timing sensors troubleshooting procedure.
3. Check for Intermittent Diagnostic Codes Intermittent Result: Intermittent codes are present.
Codes
A. Certain diagnostic codes may cause poor performance. Connect Repair: Troubleshoot any codes that are present before
the electronic service tool and check for active codes and/or for continuing with this procedure.
logged codes.
Result: Intermittent codes are not present.
4. Intermittent Throttle Signal Throttle Signal Result: The status for “Throttle Position” is stable.
A. Monitor the status for “Throttle Position” on the electronic service Proceed to Test Step 5.
tool.
Result: The status for “Throttle Position” is not stable.
B. Verify that the status for “Throttle Position” is stable and that the
engine is able to reach high idle speed. Repair: Make the necessary repairs. Refer to Trouble-
shooting, “Speed Control - Test”.
Refer to Troubleshooting, “Speed Control - Test”.
5. Fuel System Fuel System Result: The “Fuel System Verification Test” was
Verification successful.
A. Ensure that the fuel system is operating properly. Test
Result: The “Fuel System Verification Test” was not
C. Perform the “Fuel System Verification Test” on the electronic serv- successful.
ice tool.
Repair: Repair the cylinders that failed the “Fuel System
Verification Test” . Reset all active codes and clear all
logged codes. Verify that the repair has eliminated the
problem in the cylinder.
(continued)
M0070030-01 311
(Table 214, contd)

6. Fuel Supply Pressure Fuel Supply Result: The fuel supply is stable.
A. Check the fuel pressure. Ensure that the fuel is stable. Refer to Proceed to Test Step 7.
Systems Operation, Testing and Adjusting for the procedure to
check the fuel pressure manually. Result: The fuel supply is not stable.
B. Visually check the fuel level. Do not rely on the fuel gauge only. If Make the necessary repairs.
necessary, add fuel. If the engine has been run out of fuel, purge the
air from the fuel system. Verify that the repair eliminates the problem.
C. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position.
D. Check the fuel lines for the following problems:
1. Restrictions
2. Collapsed lines
3. Pinched lines
4. Loose connections
E. Prime the fuel system if any of the following procedures have

been performed:
1. Replacement of the fuel filters
2. Service on the low-pressure fuel supply circuit
3. Replacement of unit injectors
F. Check the fuel tank for foreign objects which may block the fuel
supply.
G. Check the fuel filters.
H. Check the fuel quality. Make sure that the fuel meets the require-
ments of the Operation and Maintenance Manual.
Cold weather adversely affects the characteristics of the fuel. Refer

to the Operation and Maintenance Manual for information on improv-
ing the characteristics of the fuel during cold-weather operation.
7. Restriction in the Air Inlet and Exhaust System Restrictions Result: There are restrictions in the air inlet or exhaust
system.
Inlet air restrictions or exhaust system restrictions can cause a high
exhaust temperature. Repair: Repair the restrictions or remove the
restrictions.
The Engine Control Module (ECM) monitors the following parame-
ters to calculate an exhaust temperature:
· Barometric pressure
· Intake manifold air temperature
· Engine speed
Certain operating conditions may cause the calculated exhaust tem-

perature to increase to a level that may damage engine compo-
nents. If a high exhaust temperature occurs, the ECM derates the
(continued)
312 M0070030-01
(Table 214, contd)

engine to reduce the calculated exhaust temperature. The engine is
derated only to a level that allows the calculated exhaust tempera-
ture to return to an acceptable level.
Refer to the High Exhaust Temperature Prevention Derate Time His-

togram for derate information.
A. Ensure that the turbocharger is operating correctly. Periodic in-

spection and cleaning are recommended for the turbocharger com-
pressor housing (inlet side).
B. Check the air filter restriction indicator. Clean plugged air filters or
replace plugged air filters.
C. Check the air inlet and exhaust system for restrictions and/or
leaks.
i06676072
SCR Warning System Problem
Operator Level Inducement

Inducements are engine derates, vehicle speed
limits, or other actions intended to prompt the
operator to repair or maintain the emissions control
system.
Inducement strategies are control actions required by
EPA/ARB Tier 4 final and EU Stage IV regulations.
These control actions ensure prompt correction of
various failures in the engine NOx emissions control
system. Actions are required to limit engine
performance and define required indications such as
visual alarms including lamps and messages, as well
as audible alarms, when the control actions are
imposed.
Table 215
This code is a Level 3 inducement associated with

Aftertreatment SCR Operator In- an emissions system fault. The engine is derated
5246-0 E1389 (3)
ducement Severity (3) 100%, limited to low idle or 1000 RPM, and can ex-
perience 5 minute rolling shutdowns.
Aftertreatment SCR Operator In- This code is a Level 1 inducement associated with
5246-15 E1389 (1)
ducement Severity (1) an emissions system fault.
Aftertreatment SCR Operator In- This code is a Level 2 inducement associated with
5246-16 E1389 (2)
ducement Severity (2) an emissions system fault.
Refer to Systems Operation, Testing and Adjusting, Associated Codes

“DEF Dosing Control System” for details on Troubleshoot any associated diagnostic codes listed
inducement configuration options and inducement in Table 216 that are present. Refer to “Inducement
actions. Type” in Table 216 for the correct Inducement table.
M0070030-01 313
Table 216
Associated Codes
J1939 Code PDL Code Code Description Inducement Type
J1939 Network #2 : Abnormal Up- Category 1

1231-9 2348-9
date Rate
J1939 Network #2 : Special Category 2
1231-14 2348-14
Instruction
J1939 Network #3 : Abnormal Up- Category 1
1235-9 5856-9
date Rate
J1939 Network #3 : Special Category 2
1235-14 5856-14
Instruction
Aftertreatment #1 Diesel Exhaust Category 1
1761-3 3130-3 Fluid Tank Level : Voltage Above
Normal
1761-4 3130-4 Fluid Tank Level : Voltage Below
Normal
Engine Exhaust Gas Recirculation Category 3
2659-17 E1095 (1) (EGR) Mass Flow Rate : Low -
least severe (1)
Engine Exhaust Gas Recirculation Category 3

2791-5 3405-5 (EGR) Valve Control : Current Be-
low Normal
3031-7 E1441 (2) Fluid Tank Temperature : Not Re-
sponding Properly

3031-16 E960 (2) Fluid Tank Temperature : High -

3031-18 E1398 (2) Fluid Tank Temperature : Low -
Aftertreatment #1 Intake NOx : Not Category 2

3216-7 E1431 (2)
Responding Properly
Aftertreatment #1 Intake NOx : Category 2

3216-11 3655-11
Other Failure Mode
Aftertreatment #1 Intake NOx : Category 2
3216-12 3655-12
Failure
Aftertreatment #1 Intake O2 : High Category 1
3217-16 E1407 (2)
Aftertreatment #1 Outlet NOx : Not Category 3

3226-7 E1432 (2)
Responding Properly
Aftertreatment #1 Outlet NOx : Category 3

3226-11 3609-11
Other Failure Mode
Aftertreatment #1 Outlet NOx : Category 3
3226-12 3609-12
Failure
Aftertreatment #1 Outlet O2 : High Category 1
3227-16 E1408 (2)
Aftertreatment #1 DEF Controller : Category 2

3360-3 3820-3
Voltage Above Normal
(continued)
314 M0070030-01
(Table 216, contd)

3360-4 3820-4
Voltage Below Normal

3360-9 3820-9
Abnormal Update Rate

3360-12 3820-12
Failure
3361-5 3821-5 Fluid Dosing Unit : Current Below
Normal
3361-6 3821-6 Fluid Dosing Unit : Current Above
Normal
3361-7 3821-7 Fluid Dosing Unit : Not Respond-
ing Properly

3361-11 3821-11 Fluid Dosing Unit : Other Failure
Mode
3361-14 3821-14 Fluid Dosing Unit : Special
Instruction
Sensor Supply Voltage 3 : Other Category 2
3511-11 3482-11
Failure Mode
3516-18 E1364 (2) Fluid Concentration : Low - moder-
ate severity (2)

4334-3 3090-3 Fluid Doser Absolute Pressure :


Not Responding Properly


Low - moderate severity (2)

4354-5 3110-5 Fluid Line Heater #1 : Current Be-
low Normal
4354-6 3110-6 Fluid Line Heater #1 : Current
Above Normal
low Normal
(continued)
M0070030-01 315
(Table 216, contd)

Above Normal
low Normal
Above Normal
Aftertreatment #1 SCR Catalyst In- Category 3
4360-16 E946 (2) take Gas Temperature : High -
Aftertreatment #1 SCR Catalyst In- Category 1

4360-18 E947 (2) take Gas Temperature : Low -
Aftertreatment #1 SCR Catalyst Category 1

4364-2 E1410 (2) Conversion Efficiency : Erratic, In-
termittent, or Incorrect
Aftertreatment #1 SCR Catalyst Category 3

4364-18 E1309 (2) Conversion Efficiency : Low - mod-
erate severity

4374-5 3118-5 Fluid Pump Motor Speed : Current
Below Normal
4374-6 3118-6 Fluid Pump Motor Speed : Current
Above Normal
Fluid Pump Motor Speed : Abnor-
4374-8 3118-8
mal Frequency, Pulse Width, or
Period
4376-7 3862-7 Fluid Return Valve : Not Respond-
ing Properly

5392-31 E1370 (2)
Fluid Dosing Unit Loss of Prime
Aftertreatment #1 DEF Controller Category 2

5480-16 E1430 (2) Temperature : High - moderate se-
verity (2)

5491-5 3822-5 Fluid Line Heater Relay: Current
Below Normal
5491-6 3822-6 Fluid Line Heater Relay: Current
Above Normal
Aftertreatment #1 Intake Gas Sen- Category 2
5758-11 3621-11 sor Power Supply : Other Failure
Mode
Aftertreatment #1 Outlet Gas Sen- Category 3
5759-11 3619-11 sor Power Supply : Other Failure
Mode
(continued)
316 M0070030-01
(Table 216, contd)

Aftertreatment #1 DEF Dosing Unit Category 2
5798-7 E1427 (1) Heater Temperature : Not Re-
sponding Properly
Aftertreatment #1 DEF Control Category 1

5965-5 3838-5 Module Relay Control : Current
Below Normal
Aftertreatment #1 DEF Control Category 1
5965-6 3838-6 Module Relay Control : Current
Above Normal
Table 217
1. Check for Associated Codes Associated Result: An associated code is active.

Codes
A. Connect to the electronic service tool. Repair: Troubleshoot the associated code. Refer to Trou-
bleshooting, “Diagnostic Trouble Codes” or Troubleshoot-
B. Check for an active associated code. ing, “Event Codes” for the proper procedure.
Once the associated code has been resolved, starting the

engine will remove the inducement and the inducement
code will become logged.
Engine Emissions Operator Recommended Actions

Inducement Service Mode Override Note: The procedures have been listed in order of
This override allows the service technician to disable probability. Complete the procedures in order.
the inducement to troubleshoot problems. Factory
passwords are required to activate this override.
Once the override is activated, it is possible to
navigate to other electronic service tool functions.
Usually the “Engine Emissions Operator Inducement
Service Mode Override” will not need to be activated
because the service tests performed in the applicable
troubleshooting procedure will automatically reset the
inducement. The “Engine Emissions Operator
Inducement Service Mode Override” is located in the
“Diagnostic Tests” , “System Troubleshooting
Section” of the engine ECM.
i06262532
Valve Lash Is Excessive
Probable Causes
• Valve lash setting is not at factory specifications.
• Worn rocker arms

• Worn valve springs or broken valve springs
• Bent pushrods
• Worn camshaft
• Valve seat wear
M0070030-01 317
Table 218
1. Valve Lash Setting Valve lash Result: The valve lash is set to specifications.
A. Check the engine valve lash. If necessary, adjust the engine Return the unit to service.
valve lash. Refer to Systems Operation/Testing and Adjusting
for information on adjusting the engine valve lash. Result: The valve lash cannot be set to specifications.
2. Rocker Arms Rocker arms Result: The rocker arms are damaged.
A. Inspect rocker arms for pitting or spalling on the roller. Repair: Replace parts, if necessary. If the symptom remains,
B. Check the rocker arm for a missing button.
If the problem has been corrected, return the unit to service.
Result: The rocker arms are not damaged.
3. Valve Springs Valve springs Result: The valve springs are not broken or cracked.
A. Check for cracked valve springs or broken valve springs. Proceed to Test Step 4.
Result: The valve springs are broken or cracked.
Repair: Replace parts, if necessary. If the symptom remains,

4. Pushrods Pushrods Result: The pushrods are not worn or bent.
A. Check the pushrods for wear and straightness. Proceed to Test Step 5.
B. Roll the pushrods on a flat surface in order to determine the Result: The pushrods are worn or bent.
straightness of the rod.
Repair: Replace parts, if necessary. If the symptom remains,
(continued)
318 M0070030-01
(Table 218, contd)
5. Camshaft Camshaft Result: The camshaft measured within specifications.
A. Remove the camshaft in order to inspect the camshaft. Proceed to Test Step 6.
B. Inspect the camshaft for large grooves. Result: The camshaft did not measure within specifications.
C. Measure the camshaft in order to determine if the camshaft Repair: Make the necessary repairs, If the symptom remains,
is in specifications. Refer to Specifications, “Camshaft” for the proceed to Test Step 6. If you replace the camshaft, replace
correct measurements. the valve lifters.
6. Cylinder Head Engine Result There are worn or damaged engine components.
components
A. Remove the cylinder head. Refer to the Reuse and Salvage Repair: Replace parts, if necessary.
Guidelines for the reusability specifications.
B. Inspect the piston and valve for damage.
C. Inspect the valve seat for wear.

steps are listed.
i06262547
Valve Rotator or Spring Lock

Is Free
Use this procedure in order to troubleshoot a problem

with the valve rotators or spring locks.
Probable Cause
• Valve Components
M0070030-01 319
Recommended Actions
Table 219
1. Valve Components Damaged Result: The valve components are damaged.

components
A. Inspect the following components for damage: Repair: Replace the damaged components.
1. Valve rotators A valve rotator that is cracked or a valve rotator that is

2. Spring locks broken is an indication of an engine overspeed. Deter-
3. Valve springs mine the cause of the engine overspeed. Repair the
4. Valves condition.
B. Ensure that the valve has not contacted the piston. If the
valve has contacted the piston, check the exhaust system for
debris.

steps are listed.
320 M0070030-01
Circuit Tests
Circuit Tests
i06677061
Air Shutoff - Test

codes or if the air shutoff system is not operating
properly.
Table 220
Diagnostic Codes

2813-5 3239-5 Air Shutoff Relay : Current Below The code is logged.
Normal
2813-6 3239-6 Air Shutoff Relay : Current Above The code is logged.
Normal
3667-2 E2088 (1) Engine Air Shutoff Status : Erratic, The inlet air shutoff valve switch
Intermittent, or Incorrect has been used, but the inlet air
shutoff valve feature is set as
“Disabled” in the configuration
parameters.
3667-31 E2087 (3) Engine Air Shutoff Status The engine air shutoff valve has
been activated. The engine was
shut down and injection is dis-
abled. Perform a key cycle and
reset the air inlet shutoff
system.
Note: The “Air Shutoff” parameter must be set to

“Enabled” in order for the ECM to energize the air
shutoff solenoid.
steps are listed.
M0070030-01 321
Circuit Tests
Table 221
1. Check for Diagnostic Trouble Codes Diagnostic Result: A 3667-31, or E2087 (3) code is active or
Code logged, or the air inlet shutoff valve is not working
A. Establish communication between the electronic service tool and properly.
the Electronic Control Module (ECM) . Refer to Troubleshooting,
“Electronic Service Tools”, if necessary. Proceed to Test Step 2.
B. Determine if a code is active or logged. Result: A 3239-5 or 2813-5 code is active or logged.
Result: A 3239-6 or 2813-6 code is active or logged.
Result: A 3667-2 or E2088 (1) code is active or logged.
2. Perform the “ Air Inlet Shutoff Override”” Test Result: The engine is shut down when the “Air Inlet
Shutoff Override” is activated. The air inlet shutoff is
A. Turn the key switch to the OFF position. working correctly.
B. Connect the electronic service tool to the service tool connector. Repair: Reset the air inlet shutoff system. Proceed to
Test Step 3.
C. Turn the key switch to the ON position.
Result: The engine did not shut down.
D. Place the transmission in NEUTRAL.
If the engine will not start, check the air inlet valve to ensure that the Proceed to Test Step 5.
valve is not stuck closed.
E. Start the engine. Increase the engine speed to 1500 rpm ± 100
rpm.
F. Access the “Air Inlet Shutoff Override” in the “Diagnostic Tests”

under the “Diagnostics” menu in the electronic service tool.
G. Start the test.
H. Wait for the engine to stop.
I. Stop the test.
3. Check the Air Inlet Shutoff Switch Switch Works Result: The status of the switch changed in the elec-
Correctly tronic service tool.
A. Turn the key switch to the ON position.
The inlet air shutoff switch is operating properly.
B. Connect the electronic service tool to the service tool connector.
Return to service.
C. Use the electronic service tool to monitor the status for the air in-
let shutoff switch when the switch is depressed. Result: The status of the switch did not change in the
(continued)
322 M0070030-01
Circuit Tests
(Table 221, contd)

4. Check the Circuit to the Air Inlet Shutoff Switch Circuit Result: The status changed in the electronic service
tool.
A.Turn the key switch to the OFF position.
The wiring is OK. The switch is not working properly.
B. Remove the air inlet shutoff switch.
Repair: Replace the air inlet shutoff switch. Verify that
C. Turn the key switch to the ON position. the repair eliminates the problem.
D. Connect the electronic service tool to the service tool connector. Result: The status did not change in the electronic serv-
ice tool.
E. Short the terminals of the air inlet shutoff switch together. This
short circuit will simulate the switch being closed. There is a problem with the wiring between the ECM and
the air inlet shutoff switch.
F. Use the electronic service tool to monitor the status for the air in-
let shutoff switch when the short is in place. Repair: Inspect the wiring between the ECM and the air
inlet shutoff switch. Repair the wiring or replace the wir-
ing. Verify that the repair eliminates the problem.
5. Check the Transmission Neutral Switch Transmission Result: The status of the transmission neutral switch is
Neutral Switch ON.
A. Verify that the transmission neutral switch is wired correctly.
If a transmission neutral switch is installed, the transmission must Proceed to Test Step 6.
be in neutral.
Result: The status of the transmission neutral switch is
B. Turn the key switch to the ON position. OFF.
C. Connect the electronic service tool to the service tool connector. Repair: Refer to the troubleshooting information for the
application.
D. Monitor the status for the “Transmission Neutral Switch” when
the transmission is in neutral. The status should be ON.
6. Inspect Electrical Connectors and Wiring Connectors Result: All the wires and connections are OK.
A. Turn the key switch to the OFF position. Proceed to Test Step 7.
B. Thoroughly inspect the J2/P2 ECM connector and all other con- Result: There is a problem with the wiring.
nectors in the circuit. Refer to Troubleshooting, Electrical Connec-
tors - Inspect for details. Repair: Repair the connectors or wiring and/or replace
the connectors or wiring. Ensure that all the seals are
C. Perform a 45 N (10 lb) pull test on the wires that are associated properly in place and ensure that the connectors are
with the air inlet shutoff system. coupled.
D. Check the ECM connector (allen head screw) for the proper tor- Verify that the repair eliminates the problem.
que. Refer to Troubleshooting, Electrical Connectors - Inspect for
details.
E. Check the harness and wiring for abrasion and for pinch points
from the components back to the ECM.
M0070030-01 323
Circuit Tests

Typical air inlet shutoff solenoid
Table 222
7. Check the Supply Voltage to the Air Inlet Shutoff Solenoid ±5 VDC Result:The voltage is within ±5 VDC of battery voltage
when the test is active. The ECM is properly controlling
A. Connect the electronic service tool to the service tool connector. the relay for the air inlet shutoff solenoid, but the air in-
let shutoff solenoid is not working.
B. Turn the key switch to the ON position.
Repair: Replace the air inlet shutoff solenoid. Verify
C. Perform the “Air Inlet Shutoff Override” test in the electronic serv- that the repair eliminates the problem.
ice tool.
Result: The voltage is not within ±5 VDC of battery
D. Measure the voltage across the two terminals of the air inlet shut- voltage when the test is active. The air inlet shutoff sol-
off solenoid. enoid is not receiving the correct signal.
8. Check the Signal Voltage to the Relay ±5 VDC Result: The voltage is within ±5 VDC of battery voltage
when the test is active.
A. Connect the electronic service tool to the service tool connector.
The relay is receiving the signal from the ECM. Pro-
B. Turn the key switch to the ON position. ceed to Test Step 9.
C. Perform the “Air Inlet Shutoff Override” test in the electronic serv- Result: The voltage is not within ±5 VDC of battery
ice tool. voltage when the test is active.
D. Measure the voltage across the relay coil. The relay is not receiving the signal from the ECM.
(continued)
324 M0070030-01
Circuit Tests
(Table 222, contd)

9. Check the Power Supply to the Relay ±5 VDC Result: The voltage is within ±5 VDC of battery volt-
age. The relay is receiving power.
A. Measure the voltage between the +Battery terminal of the relay
and the engine ground. Proceed to Test Step 10.
Result: The voltage is not within ±5 VDC of battery

voltage. There is a problem in the wiring between the
relay and the +Battery terminal.
Repair: Repair or replace the wiring harness. Verify

that the repair eliminates the problem.
10. Check the Output Voltage of the Relay ±5 VDC Result: The voltage is within ±5 VDC of battery volt-
age. There is a problem in the wiring between the relay
A. Ensure that all the circuits connectors are connected. and the air inlet shutoff solenoid.
B. Turn the key switch to the ON position. Repair: Repair or replace the wiring harness. Verify
C. Perform the “Air Inlet Shutoff Override” test in the electronic serv-
ice tool. Result: The voltage is not within ±5 VDC of battery
voltage. The relay is not sending power to the air inlet
D. Measure the voltage from the output terminal on the relay to the shutoff solenoid.
engine ground.
Repair: Replace the relay for the air inlet shutoff. Verify
11. Check the Wiring for an Open Circuit Short Circuit Result: A -5 code became active during the test.
A. Turn the keyswitch to the OFF position for 2 minutes. The key- The ECM did not detect the jumper wire. An open cir-
switch must be off for 2 minutes to allow the DEF pump to purge, to cuit in the wiring harness has been detected.
reset the code, and to reset the DCU.
Repair: Repair or replace the wiring harness.
B. Disconnect the air inlet shutoff relay from the wiring harness. Ver-
ify that the harness connector is free of debris, free of corrosion, Perform the “Air Inlet Shutoff Override” test again to
and securely connected. verify that the problem is resolved.
C. Connect a jumper wire between the terminals of the harness con- Result: A -6 code became active during the test.
nector for the relay coil. The coil is replaced with a short circuit.
The ECM detected the jumper wire. A failed relay has
D. Turn the key switch to the ON position. been detected.
E. Connect to the electronic service tool. Repair: Replace the air inlet shutoff relay.
F. Perform the “Air Inlet Shutoff Override” test in the electronic serv- Perform the “Air Inlet Shutoff Override” test again to
ice tool. verify that the problem is resolved.
(continued)
M0070030-01 325
Circuit Tests
(Table 222, contd)

12. Check the Wiring for a Short Circuit Open Circuit Result: A -6 code became active during the test.
A. Turn the keyswitch to the OFF position for 2 minutes. The key- The ECM did not detect the open circuit. A short circuit
switch must be off for 2 minutes to allow the DEF pump to purge, to in the wiring harness has been detected.
reset the code, and to reset the DCU.
B. Disconnect the air inlet shutoff relay from the wiring harness. Ver-
ify that the harness connector is free of debris, free of corrosion, Perform the “Air Inlet Shutoff Override” test again to
and securely connected. verify that the problem is resolved.
C. Turn the key switch to the ON position. Result: A -5 code became active during the test.
D. Connect to the electronic service tool. The ECM detected the open circuit. A failed relay has
been detected.
E. Perform the “Air Inlet Shutoff Override” test in the electronic serv-
ice tool. Repair: Replace the air inlet shutoff relay.
Perform the “Air Inlet Shutoff Override” test again to

verify that the problem is resolved.
13. Check the Configuration Parameters “Inlet Air Shutoff Result: The “Inlet Air Shutoff Valve” feature is “Dis-
Valve” Feature is abled” and a switch is installed.
A. Turn the key switch to the ON position. “Disabled”
Repair: Change the configuration parameter to “En-
B. Connect to the electronic service tool and navigate to the “Con- abled” .
figuration Tools” screen.
C. Check the status of the “Inlet Air Shutoff Valve” in the “Engine
Configuration Parameters” menu.
i06677080
Aftertreatment Identification
Module - Test
Table 223 lists the diagnostic trouble codes for the

Aftertreatment Identification Module.
326 M0070030-01
Circuit Tests
Table 223
Code Description
J1939 PDL (code descriptions may Comments
Code Code vary)
The installed Clean Emissions Module (CEM) #1 is not a certified match with the
engine.
Aftertreatment #1 Identification The code is a confirmed emissions regulation violation. A financial penalty and/or le-
5576-2 3468-2 : Erratic, Intermittent, or gal action may result, if the problem is not corrected immediately. Do not operate the
Incorrect engine with the active fault.
Engine power is derated.
Emissions do not conform to regulations. Do not continue to operate the engine with
Aftertreatment #1 Identification
the active fault.
5576-8 3468-8 : Abnormal Frequency, Pulse
Width, or Period
The installed Clean Emissions Module (CEM) #2 is not a certified match with the
engine.
Aftertreatment #2 Identification The code is a confirmed emissions regulation violation. A financial penalty and/or le-
5577-2 3469-2 : Erratic, Intermittent, or gal action may result, if the problem is not corrected immediately. Do not operate the
Incorrect engine with the active fault.
Emissions do not conform to regulations. Do not continue to operate the engine with
Aftertreatment #2 Identification
the active fault.
5577-8 3469-8 : Abnormal Frequency, Pulse
Width, or Period

steps are listed.
Table 224
1. Check for Diagnostic Trouble Codes Diagnostic Result: A 3468-2, 3468-8, 5576-2, 5576-8, 3469-2, 5577-
Trouble 2, 3469-8, or 5577-8 diagnostic code is active.
A. Establish communication between the electronic service tool and Codes
the Electronic Control Module (ECM) . Refer to Troubleshooting, Proceed to Test Step 2.
M0070030-01 327
Circuit Tests

Typical CEM identification plate

CEM (typical)
(1) Typical location of CEM identification
plate
328 M0070030-01
Circuit Tests
Table 225
2. Manually Enter the Aftertreatment Identification Information Certified Result: The affected CEM is a certified match with the
Match engine.
The CEM identification plate is on the electronics panel.
Factory Passwords are required for this procedure. Proceed to Test Step 3.
A. Confirm that a certified CEM is installed on the engine. Result: The affected CEM is not a certified match for the
Contact your local Perkins distributor for a list of approved CEM and engine.
RF configurations for your engine.
Repair: Remove the affected CEM and replace the af-
B. Record the affected CEM serial number and the configuration fected CEM with a certified match for the engine. Refer to
group from the CEM Identification Plate. Disassembly and Assembly for removal and installation
procedures. When the new CEM is installed, the “After-
C. Verify that the affected CEM is a certified match with the engine. treatment Identification Number Module” will begin com-
Contact the Dealer Solutions Network (DSN), if necessary. municating with the ECM and the diagnostic code will be
cleared.
The engine ECM will only communicate with the CEM

if the total lifetime hours of the engine are less than
100. If the hours are greater than 100, the information
from the CEM identification plate must be programmed
into the ECM by using the electronic service tool.
M0070030-01 329
Circuit Tests
Table 226
3. Aftertreatment Configuration CEM Result: The diagnostic code is automatically cleared.

Configuration
A. Establish communication between the electronic service tool and Return to service.
the affected ECM. Refer to Troubleshooting, “Electronic Service
B. Navigate to the “Aftertreatment Configuration” in the affected “En-

gine Aftertreatment Controller” page.
C. Program the required “Factory Installed Aftertreatment Identifica-

tion Number” with the serial number from the CEM Identification
Plate.
330 M0070030-01
Circuit Tests
i06677124
ARD Combustion Air - Test
Table 227 lists the diagnostic codes that relate to the

combustion air system.

Table 227
Description
J1939 Code PDL Code
There is low current flow in the wiring between the
ARD Air Pressure Control Actuator : Current combustion air valve and the A5:E2 aftertreatment
3487-5 2489-5
Below Normal controller. Regenerations are disabled. The code
is logged.
There is excessive current flow in the wiring be-

ARD Air Pressure Control Actuator : Current tween the combustion air valve and the A5:E2
3487-6 2489-6
Above Normal aftertreatment controller. Regenerations are dis-
abled. The code is logged.
The combustion air valve is not responding prop-

ARD Air Pressure Control Actuator : Not Re-
3487-7 E1041 (1) erly to commands from the A5:E2 aftertreatment
sponding Properly
controller. The code is logged.
There is excessive voltage on the signal wire be-

tween the combustion air valve and the A5:E2
ARD Air Pressure Control Actuator Position
3488-3 2490-3 aftertreatment controller or there is an open circuit
Sensor : Voltage Above Normal
on the supply, signal, or return wire. The code is
logged. Engine power is derated.
There is low voltage on the signal wire between

ARD Air Pressure Control Actuator Position the combustion air valve and the A5:E2 aftertreat-
3488-4 2490-4
Sensor : Voltage Below Normal ment controller. The code is logged. Engine power
is derated.
M0070030-01 331
Circuit Tests

steps are listed.
Table 228
1. Determine the Diagnostic Code Diagnostic Result: A E1041 (1) or a 3487-7 code is logged or
Code active.
A. Establish communication between the electronic service tool and
the “Engine #1 Aftertreatment Controller” . Refer to Troubleshooting, Proceed to Test Step 2.
Result: A 2490-3, 2490-4, 3488-3, or a 3488-4 code is
B. Record the logged codes or the active codes. logged or active. There is a problem with the wiring be-
tween the A5:E2 aftertreatment controller and the com-
bustion air valve.
Result: A 2489-6 or a 3487-6 code is logged or active.

There is a problem with the wiring between the A5:E2
aftertreatment controller and the combustion air valve.
Result: A 2489-5, or a 3487-5 code is logged or active.

There is a problem with the wiring between the A5:E2
aftertreatment controller and the combustion air valve.
332 M0070030-01
Circuit Tests
Table 229
2. Inspect the Wiring to the Actuator Damaged Wire or Result: A damaged wire or damaged connector was
Connector not found.
A. Inspect the wiring from the A5:E2 aftertreatment controller to
the actuator for the combustion air. Proceed to Test Step 3.
B. Check all connectors. Refer to Troubleshooting, “Electrical Result: A damaged wire or damaged connector was
Connectors - Inspect”. found.
C. Check the wires for damage to the insulation. Repair: Repair the damaged wire or the damaged
D. Inspect the wires for the following conditions:
1. Exposed insulation
2. Rubbing of a wire against the engine
3. Rubbing of a wire against a sharp point
E. Perform a pull test on each wire terminal connection. Refer to

Troubleshooting, “Electrical Connectors - Inspect”.
3. Perform the “ ARD Air System Service Test”” Test Result: The “ARD Air System Service Test” passed.
A. Perform the “ARD Air System Service Test” in the electronic Proceed to Test Step 12
service tool.
Result: The “ARD Air System Service Test” failed.
M0070030-01 333
Circuit Tests
(1) Inspection points between the head

compressed air supply and the ARD
Table 230
4. Inspect the Piping Between the Compressor and the Com- Damaged Result: The tube is damaged or cracked.
bustion Air Valve Tubing
Repair: Replace the tubing or repair the tubing. Proceed
A.Inspect the tube between the compressor and the combustion air to Test Step 6.
valve.
Result: The tube is not damaged or cracked.
B. Check for cracks in the tubing.
334 M0070030-01
Circuit Tests

CEM (typical)
(2) Piping between the combustion air valve pressure sensor
and the combustion air absolute (3) Clamps
M0070030-01 335
Circuit Tests
Table 231
5. Inspect the Tubing from the Combustion Air Valve to the Com- Damaged Result: The tube is damaged or cracked.
bustion Air Absolute Pressure Sensor Tubing
Repair: Replace the tubing or repair the tubing. Pro-
A. Inspect the tubing from the combustion air valve to the combustion ceed to Test Step 6.
air absolute pressure sensor.
Result: The tube is not damaged.
B. Check for cracks in the tubing.
Repair: Replace the combustion air valve. Proceed to
C. Check for air leaks. Test Step 6.
D. Check the clamps on the tube. Make sure that the clamps are tight.
6. Perform the “ ARD Air System Service Test”” Test Result: The “ARD Air System Service Test” passed.
A. Perform the “ARD Air System Service Test” in the electronic serv- Proceed to Test Step 12.
ice tool.
Result: The “ARD Air System Service Test” failed.
Repair: Replace the combustion air valve. Verify the

repair by repeating the “ARD Air System Service Test”
. Proceed to Test Step 12.
7. Check the Voltage on the Combustion Air Valve Circuit +5 VDC Result: There is 5 VDC between the SUPPLY and RE-
TURN on the combustion air valve connector.
B. Verify that the harness connector is free of debris, free of corrosion
and securely connected. Result: There is not 5 VDC between the SUPPLY and
RETURN on the combustion air valve connector.
C. Disconnect the combustion air valve from the wiring harness.
There is a problem with the wiring harness or the A5:
D. Turn the keyswitch to the ON position. E2 aftertreatment controller.
E. Verify that there is +5 VDC between the SUPPLY (terminal 1) and Repair: Make the necessary repairs. Replace parts, if
RETURN (terminal 2) on the combustion air valve wiring harness necessary.
connector.
F. Turn the keyswitch OFF.
8. Create an Open at the Combustion Air Valve Connector Active -3 Code Result: A -3 diagnostic code became active after dis-
connecting the combustion air valve.
A. Turn the keyswitch OFF.
B. Disconnect the combustion air valve from the wiring harness.
Result: A -3 diagnostic code did not become active
C. Turn the keyswitch ON. after disconnecting the combustion air valve.
D. Monitor the diagnostic codes on the electronic service tool. Check There is a problem with the wiring harness or the A5:
for an active -3 diagnostic code for the combustion air valve. E2 aftertreatment controller.
E. Turn the keyswitch OFF. Repair: Make the necessary repairs. Replace parts, if
necessary.
(continued)
336 M0070030-01
Circuit Tests
(Table 231, contd)

9. Create a Short at the Sensor Connector Active -4 Code Result: A -4 diagnostic code became active after cre-
ating the short at the combustion air valve connector.
The wiring is OK. Replace the combustion air valve.
B. Create a short between the SIGNAL (terminal 3) and RETURN
(terminal 2) at the combustion air valve connector. Proceed to Test Step 12.
C. Turn the keyswitch ON. Result: A -4 diagnostic code did not become active
after creating the short at the combustion air valve
D. Monitor the diagnostic codes on the electronic service tool. Check connector.
for an active -4 diagnostic code for the combustion air valve.
E. Turn the keyswitch OFF. E2 aftertreatment controller.

necessary.
10. Create an Open at the Combustion Air Valve Connector Active -5 Code Result: A -5 diagnostic code became active after dis-
connecting the combustion air valve.
The wiring is OK. Replace the combustion air valve.
B. Verify that the harness connector is free of debris, free of corrosion
and securely connected. Proceed to Test Step 12.
C. Disconnect the combustion air valve from the wiring harness. Result: A -5 diagnostic code did not become active
after disconnecting the combustion air valve.
E. Monitor the diagnostic codes on the electronic service tool. Check E2 aftertreatment controller.
for an active -5 diagnostic code for the combustion air valve.
F. Turn the keyswitch OFF. necessary.
(continued)
M0070030-01 337
Circuit Tests
(Table 231, contd)

11. Create a Short at the Sensor Connector Active -6 Code Result: A -6 diagnostic code became active after cre-
ating the short at the combustion air valve connector.
Repair: The wiring is OK. Replace the combustion air
B. Verify that the harness connector is free of debris, free of corrosion valve.
and securely connected.
C. Disconnect the combustion air valve from the wiring harness.
Result: A -6 diagnostic code did not become active
D. Create a short between the Command (+) (terminal 6) and Com- after creating the short at the combustion air valve
mand (-) (terminal 4) at the combustion air valve connector. connector.
E. Turn the keyswitch ON. There is a problem with the wiring harness or the A5:
E2 aftertreatment controller.
F. Monitor the diagnostic codes on the electronic service tool. Check
for an active -6 diagnostic code for the combustion air valve. Repair: Make the necessary repairs. Replace parts, if
necessary.
G. Turn the keyswitch OFF.
12. Perform an ARD Ignition Test Test Result: The ARD ignition test completes successfully.
A. Perform an ARD ignition test using the electronic service tool. Re- Return to service.
fer to System Operation, Testing and Adjusting, “ARD Fuel System -
Test”. Result: The ARD ignition test is not successful and
additional codes are logged.
The ARD Ignition Test cannot be performed if the DPF soot loading is
above 80%. When the DPF soot loading is above 80%, the Manual Repair: Troubleshoot the codes. Refer to Trouble-
DPF Regeneration must be performed using the electronic service shooting for the correct procedure.
tool.
i06677212
ARD Fuel Supply - Test

steps are listed.
Table 232
1. Check the Fuel Level Fuel Level Result: The fuel level is OK.
A. Remove the fuel tank cap from the fuel tank. Proceed to Test Step 2.
B. Check the vent port that is in the cap for debris. Remove any de- Result: The fuel level is low.
bris with compressed air.
Repair: Fill the tank with fuel. Proceed to Test Step 6.
C. Visually inspect the fuel level in the tank. Ensure that the fuel
tank has enough of fuel to operate the engine.
D. Check the position of the fuel supply valve (if equipped). The
valve must be in the full OPEN position.
338 M0070030-01
Circuit Tests
Table 233
Required Tools
Pressure gauge capable of measuring up to 3447 kPa (500 psi)
(1) Output port of the pump
M0070030-01 339
Circuit Tests

Assembled required parts
Table 234
2. Check the Fuel Pressure at the ARD Fuel Supply 1900 ± Result:The pressure measured 1900 ± 120 kPa
120 kPa (276 ± 17 psi).
A. Disconnect the ARD fuel line from the pump. (276 ± 17
psi) Proceed to Test Step 6.
B. Install the pressure gauge at the pump outlet port.
Result:The pressure is less than1900 ± 120 kPa
C. Turn the keyswitch to the ON position. Start the engine. (276 ± 17 psi).
D. Establish communication between the electronic service tool and Repair: Replace the primary fuel filter. Proceed to Test Step
the “Engine #1 Aftertreatment Controller” . 3.
E. Select the “Aftertreatment Fuel Pump Relay Override” to activate Result:The pressure measured 0 kPa (0 psi).
the pump.
Inspect the wiring at the pump. If the wiring is OK and the
F. Override the pump and record the pressure from the pressure pump does not activate, replace the pump cartridge. Refer to
gauge. Disassembly and Assembly, Fuel Priming Pump - Remove
and Install.
G. Deactivate the override.
I. The pressure must be within specifications. The pump pressure

must be 1900 ± 120 kPa (276 ± 17 psi).
340 M0070030-01
Circuit Tests
M0070030-01 341
Circuit Tests
Table 235
3. Check the Pressure Regulator 1900 ± 120 kPa Result: The pressure measured 1900 ± 120 kPa
(276 ± 17 psi) (276 ± 17 psi).
A. Turn the keyswitch to the ON position. Start the
B. Establish communication between the electronic serv- Result: The pressure did not measure
ice tool and the “Engine #1 Aftertreatment Controller” . 1900 ± 120 kPa (276 ± 17 psi).
Select the “Aftertreatment Fuel Pump Relay Override” to Repair: Replace the fuel pressure regulator on the
activate the pump. pump base.
C. Record the pressure on the pressure gauge. Proceed to Test Step 4.
D. Turn the keyswitch to the OFF position.
4. Check the ARD Fuel Pump 1900 ± 120 kPa Result:The pressure measured 1900 ± 120 kPa
(276 ± 17 psi) (275.5 ± 17.4 psi).
A. Turn the keyswitch to the ON position. Start the engine.
and the “Engine #1 Aftertreatment Controller” .
Result:The pressure did not measure 1900 ± 120 kPa
C. Select the “Aftertreatment Fuel Pump Relay Override” to acti- (275.5 ± 17.4 psi).
vate the pump.
Repair: Replace the ARD fuel pump cartridge. Refer to
D. Record the pressure on the pressure gauge. Disassembly and Assembly, Fuel Priming Pump - Re-
move and Install
5. Check the Fuel Diverter Valve 1900 ± 120 kPa Result:The pressure measured 1900 ± 120 kPa
(276 ± 17 psi) (275.5 ± 17.4 psi).
A. Turn the keyswitch to the ON position. Start the engine.
and the “Engine #1 Aftertreatment Controller” .
Result:The pressure did not measure 1900 ± 120 kPa
C. Select the “Aftertreatment Fuel Pump Relay Override” to acti- (275.5 ± 17.4 psi).
vate the pump.
Repair: Replace the fuel diverter valve.
D. Record the pressure from the pressure gauge.
6. Perform a Manual DPF Regeneration Successful Result:The manual DPF regeneration completed
Regeneration successfully.
This test must be performed through the electronic service tool.
The electronic service tool enhances the diagnostics during the Return to service.
service test.
Result:The manual DPF regeneration did not complete
A. Turn the keyswitch to the ON position. Start the engine. successfully.
B. Establish communication between the electronic service tool Repair: Check the list of active diagnostic codes. Trou-
and the “Engine #1 Aftertreatment Controller” . bleshoot the code that applies to the failed regeneration.
C. Start a Manual DPF regeneration using the electronic service

tool.
342 M0070030-01
Circuit Tests
i06677711
ARD Ignition - Test

code.


Table 236
Code Description
J1939 Code PDL Code Comments
The current flow through the primary ignition circuit is below the
Aftertreatment #1 Ignition Transformer
3484-5 2465-5 threshold. A snapshot is triggered. If active regeneration is in
Primary : Current Below Normal
progress, the ARD completes the regeneration.
The current flow through the primary ignition circuit is above the
3484-6 2465-6 threshold. A snapshot is triggered. If active regeneration is in
Primary : Current Above Normal
progress, the ARD completes the regeneration.
The ARD has attempted to ignite three times. All the attempts
were unsuccessful. The ECM has detected a problem with the
current flow through the secondary circuit. The primary circuit is
OK.
The spark plug is fouled.
Aftertreatment #1 Ignition Transformer or
4265-5 3180-5
Secondary : Current Below Normal There is a problem with the ignition wire between the ignition
coil and the spark plug. These problems usually occur because
the ignition wire has been damaged by excessive heat or im-
proper routing.
or
The ignition coil has a problem.
Table 237
Required Tooling for the Procedure
T400026 Spark Tester

steps are listed.
M0070030-01 343
Circuit Tests
Table 238
1. Determine the Diagnostic Code Diagnostic Result: A 2465-5, 2465-6, 3484-5 or 3484-6 code is
Code present.
B. Use the “Aftertreatment #1 Ignition Transformer Primary Override”
on the electronic service tool to turn on the ARD ignition system. The Result: A 3180-5 or 4265-5 code is present or a diagnos-
ARD ignition system must operate for 20 seconds in order for a diag- tic code is not present.
nostic trouble code to become active. securely.
C. Determine the diagnostic code that is present.
2. Inspect the Ignition Wire Damaged Result: The ignition wire is not damaged.
Wire
A. Visually inspect the ignition wire between the ignition coil and the Proceed to Test Step 3.
ARD combustion head. Look for the following problems:
Result: The ignition wire is damaged.
Repair: Replace the ignition wire. Proceed to Test Step
2. Moisture on the connectors or the ignition wire 7.
3. Damage to the ignition wire that is caused by excessive heat
4. Damage to the ignition wire that is caused by chafing
5. Improper routing of the ignition wire
6. Damaged insulation on the ignition wire
B. Push the boot on each end of the ignition wire. This action tests
whether the clip inside the boot is connected to the spark plug and to
the ignition coil. There should be a “click” when you push the boot
onto either part. If you felt a “click” , the clip inside the boot was not
previously connected.
(1) T400026 Spark Tester
344 M0070030-01
Circuit Tests
Table 239
3. Check for Spark at the Coil Output, Using the Spark Indicator Spark Result: Spark is present in the indicator.
A. Assemble the T400026 Spark Tester as shown in Illustration 117 Proceed to Test Step 4.
.
Ensure that the alligator clip is secured to a good ground source. Result: Spark is not present in the indicator.
B. Install the spark indicator as shown in illustration 118 . Repair: Replace the ignition coil. Proceed to Test Step 7.
C. Use the “Aftertreatment #1 Ignition Transformer Primary Override”

on the electronic service tool to turn ON the ARD ignition system.
Check for spark in the spark indicator.
M0070030-01 345
Circuit Tests
Table 240
4. Check for Spark to the Spark Plug Spark Result: Spark is present in the indicator.
A. Assemble the T400026 Spark Tester as shown in Illustration 119 Repair: Replace the spark plug. Proceed to Test Step 7.
.
Result: Spark is not present in the indicator.
B. Install the spark plug indicator between the spark plug and the
end of the spark plug wire. Repair: Replace the ignition wire. Proceed to Test Step 7.
C. Use the “Aftertreatment #1 Ignition Transformer Primary Override”

on the electronic service tool to turn ON the ARD ignition system.
Check for spark in the spark indicator.
346 M0070030-01
Circuit Tests

Information for the ignition circuit.
Table 241
5. Check for Voltage at the Ignition Coil Greater than Result: The voltage between terminal 1 and terminal 3 is
1.5 VDC ±.5 greater than 1.5 VDC ±.5 VDC.
A. Disconnect the connector from the ignition coil. VDC
Not all connectors may be shown in the illustration above, refer to Proceed to Test Step 6.
the electrical schematic.
Result: The voltage between terminal 1 and terminal 3 is
B. Turn the keyswitch to the “ON” position. less than 1.5 VDC ±.5 VDC.
C. Establish communication between the electronic service tool and Repair: The problem is in the wiring between the ECM
the ECM . Refer to Troubleshooting, “Electronic Service Tools”, if and the ignition coil connector. Repair the wiring or replace
necessary. the wiring. Proceed to Test Step 7.
D. Use the Aftertreatment #1 Ignition Transformer Primary Override

in the electronic service tool to turn ON the ARD ignition system.
Measure the voltage between terminal 1 and terminal 3 on the Clean
Emissions Module (CEM) harness connector for the ignition coil.
E. Turn off the ARD ignition system by disabling the override.
M0070030-01 347
Circuit Tests
Table 242
6. Check the Ground for the Ignition Coil Greater than Result: The voltage between terminal 1 and terminal 2 is
1.5 VDC ±.5 greater than 1.5 VDC ±.5 VDC.
A. Disconnect the connector from the ignition coil. VDC
Repair: Replace the ignition coil. Proceed to Test Step 7.
Result: The voltage between terminal 1 and terminal 2 is
C. Establish communication between the electronic service tool and less than 1.5 VDC ±.5 VDC.
the ECM . Refer to Troubleshooting, “Electronic Service Tools”, if
necessary. Repair: The problem is in the wiring between the ground
point and the ignition coil connector. Repair the wiring or
Use the Aftertreatment #1 Ignition Transformer Primary Override in replace the wiring. Proceed to Test Step 7.
the electronic service tool to turn ON the ARD ignition system.
Measure the voltage between terminal 1 and terminal 2 on the
Clean Emissions Module (CEM) harness connector for the ignition
coil.
Turn off the ARD ignition system by disabling the override.
7. Check the ARD for Proper Operation Successful Result: The test is successful.
Test
A. Perform the ARD Ignition Test using the electronic service tool. Return the unit to service.
The test runs for approximately 5 minutes.
Result: The test is not successful and additional codes
The ARD Ignition Test cannot be performed if the DPF soot are logged.
80%, the Manual DPF Regeneration must be performed using Repair: Troubleshoot the codes. Refer to Troubleshooting,
the electronic service tool. Event Codes or Troubleshooting, Diagnostic Trouble Co-
des for the correct procedure.
i06677795
ARD Nozzle Heater - Test
The ARD nozzle can become plugged with carbon or

with debris. The engine is equipped with a system
that cleans the nozzle. The A5:E2 Aftertreatment
Controller periodically tests the condition of the
nozzle. The ARD combustion head contains an
electric heating element. The heating element
operates periodically to clean the nozzle.
This test is to verify the correct operation of the ARD
nozzle heater electrical circuit.
NOTICE
On some industrial engine applications, the engine
may be fitted with a power converter. This device al-
lows a 24V Clean Emissions Module (CEM) to be in-
stalled on a 12V engine. If this component fails, the
A5: E2 Aftertreatment Controller may log codes re-
lated to the ARD nozzle heater.
348 M0070030-01
Circuit Tests
Table 243
Code Description
Aftertreatment #1 Fuel Injector #1 Heater High voltage or an open circuit has been detected in the ARD
4301-3 3182-3
Control : Voltage Above Normal nozzle heater circuit
Aftertreatment #1 Fuel Injector #1 Heater Low voltage or a short circuit has been detected in the ARD noz-
4301-4 3182-4
Control : Voltage Below Normal zle heater circuit.

steps are listed.
Table 244
1. Check the Device that is Used for Circuit Protection 12V to 16V Result: The voltage is equal to system voltage on both
on a 12V sides of the device that is used for circuit protection.
References will be made to system voltage. The system voltage of a System
typical 12V system is usually 12V to 16V. or Proceed to Test Step 4.
24V to 28V
The system voltage of a typical 24V system is usually 24V to 28V. on a 24V Result: The voltage is not equal to system voltage on the
System supply side of the circuit protection device.
A. Measure the voltage on the supply side of the device that is used
for circuit protection. Refer to the application-specific schematic for Repair: The problem is in the wiring to the battery. Repair
the location of the circuit protection device. the wiring. Proceed to Test Step 11.
B. Measure the voltage on the load side of the device that is used for Result: The voltage is not equal to system voltage on the
circuit protection. load side of the circuit protection device.
On industrial engines, refer to the appropriate schematic to deter- Proceed to Test Step 2.
mine if a power converter is installed. On these systems the device
used for circuit protection is on the 12V side.
2. Reset the Protection Device Circuit Pro- Result: The circuit protection trips.
tection De-
A. Reset the protection device or replace the circuit protection vice or Proceed to Test Step 3.
device. Circuit
Result: The circuit protection does not trip.
C. Perform the “ARD Nozzle Heater Circuit Test” in the electronic
service tool.
3. Check the ARD Head ARD Head Result: The circuit protection trips.
A. Turn the key to the OFF position There is a problem in the wiring circuit for the ARD heater.
B. Disconnect the connector to the heater at the ARD head.
Result: The circuit protection does not trip.
C. Reset the protection device or replace the circuit protection
device. Repair: Replace the ARD head.
D. Start the engine. Inspect the coolant supply and return lines to the ARD
head for restrictions or blockage.
E. Perform the “ARD Nozzle Heater Circuit Test” in the electronic
service tool. Proceed to Test Step 11.
M0070030-01 349
Circuit Tests
350 M0070030-01
Circuit Tests
Table 245
4. Check for Output Voltage from the ARD Heater Relay Equal to Result: The voltage between terminal 2 on the ARD heater
System relay and a good ground is not equal to system voltage.
A. Turn the keyswitch to the ON position. Do not start the engine. Voltage
B. Measure the voltage between terminal 2 and a good ground
source. Result: The voltage between terminal 2 on the ARD heater
relay and a good ground is equal to system voltage.
Note: On industrial engines that use the power converter, the system
voltage is 24V on the switch side of the relay. Repair: The ARD heater relay is not operating properly.
Replace the ARD heater relay. Proceed to Test Step 12.
5. Check for System Voltage at the ARD Heater Relay Equal to Result: The voltage between terminal 3 and terminal 4 on
System the ARD heater relay is equal to system voltage.
A. Turn the keyswitch to the “ON” position. Voltage
B. Measure the voltage between terminal 3 and terminal 4 on the
ARD heater relay. Result: The voltage between terminal 3 and terminal 4 on
the ARD heater relay is not equal to system voltage.
On industrial engines that use the power converter, the system volt-
age is 24V on the switch side of the relay. Repair: The problem is between terminal 3 on the ARD
heater relay and the circuit protection device or the prob-
lem is that terminal 4 does not have a good ground source.
Repair the problem. Proceed to Test Step 12.
M0070030-01 351
Circuit Tests

CEM (typical example)
(1) Two-pin ARD heater wire connector (2) ARD Nozzle heater relay (3) ARD head
Table 246
6. Check for System Voltage at the Two-Pin ARD Heater Wire Equal to Result: The voltage between battery ground and terminal 1
Connector System is equal to system voltage.
Voltage
A. Start the engine. Proceed to Test Step 7.
B. Establish communication between the electronic service tool and Result: The voltage between battery ground and terminal 1
the A5:E2 Aftertreatment Controller. is not system voltage.
C. Perform the “ARD Nozzle Heater Circuit Test” . Proceed to Test Step 9.
D. Measure the voltage between battery ground and terminal 1 on the

two-pin ARD heater wire connector.
352 M0070030-01
Circuit Tests

ARD combustion head
(4) Port for the heated nozzle
(5) Connector for the heated nozzle (6) Measurement location on the wire
M0070030-01 353
Circuit Tests
Table 247
7. Check for Voltage at the ARD Head Equal to Result: The voltage is equal to system voltage.
System
A. Remove the retaining clip from the ARD nozzle heater. Voltage Proceed to Test Step 8.
B. Disconnect the wire to the ARD nozzle heater. Result: The voltage is not equal to system voltage.
C. Start the engine. Repair: Repair the wiring or replace the wiring between the
two-pin connector and the ARD nozzle heater. Proceed to
D. Establish communication between the electronic service tool and Test Step 12.
the A5:E2 Aftertreatment Controller .
E. Perform the “ARD Nozzle Heater Circuit Test” .
F. Check for voltage at the connector for the ARD nozzle heater. Refer
to Illustration 124 for the proper measurement location.
Power to the A5:E2 Aftertreatment Controller must be OFF before re-

connecting the relay.
System voltage is typically ± 5 VDC of battery voltage.
On industrial engines that use the power converter the system voltage
is 24V on the ARD Head.
8. Check for System Voltage at the A5:E2 Aftertreatment Equal to

Controller System Result: The voltage between battery ground and pin 7 is
Voltage equal to system voltage.
Repair: Replace the ARD head.
B. Establish communication between the electronic service tool and
the A5:E2 Aftertreatment Controller. Inspect the coolant supply and return lines to the ARD head
for restrictions or blockage.
C. Perform the “ARD Nozzle Heater Circuit Test” .
D. Measure the voltage between battery ground and pin 7 at the J1
connector. Result: The voltage between battery ground and pin 7 is
not system voltage.
Repair: Repair the wiring or replace the wiring between the

two-pin connector and the A5:E2 Aftertreatment Controller.
9. Check for Output Voltage from the ARD Heater Relay Equal to Result: The voltage between terminal 2 and battery ground
System is equal to system voltage.
A. Start the engine. Voltage
Repair: The problem is between terminal 2 on the ARD
B. Establish communication between the electronic service tool and heater relay and the two-pin ARD heater wire connector.
the A5:E2 Aftertreatment Controller . Repair or replace the damaged wire. Proceed to Test Step
11.
Result: The voltage between terminal 2 and battery ground
D. Measure the voltage between terminal 2 on the ARD heater relay is not equal to system voltage.
and battery ground.
Power to the ECM must be OFF before reconnecting the relay.
is 24V on the switch side of the relay.
(continued)
354 M0070030-01
Circuit Tests
(Table 247, contd)

10. Check for Signal Voltage at the ARD Heater Relay Signal Result: The voltage between terminal 1 and terminal 4 on
Voltage (5 the ARD heater relay is signal voltage.
A. Start the engine. VDC)
Repair: The ARD heater relay is not operating properly. Re-
B. Establish communication between the electronic service tool and place the ARD heater relay. Proceed to Test Step 12.
the A5:E2 Aftertreatment Controller . Refer to Troubleshooting, “Elec-
tronic Service Tools”, if necessary. Result: The voltage between terminal 1 and terminal 4 on
the ARD heater relay is not signal voltage.
D. Measure the voltage between terminal 4 and terminal 1 on the
ARD heater relay.

is 24V on the switch side of the relay.
11. Check for Signal Voltage at the A5:E2 Aftertreatment Signal Result: The voltage between A5:E2 Aftertreatment Control-
Controller voltage (5 ler terminal 43 and terminal 41 is signal voltage.
VDC)
A. Start the engine. Repair: Repair or replace the wiring between the A5:E2
Aftertreatment Controller and the ARD heater relay.
the A5:E2 Aftertreatment Controller. Refer to Troubleshooting, “Elec- Proceed to Test Step 12.
tronic Service Tools”, if necessary.
Result: The voltage between A5:E2 Aftertreatment Control-
C. Perform the “ARD Nozzle Heater Circuit Test” . ler terminal 43 and terminal 41 is not signal voltage.
D. Measure the voltage between terminal 41 and terminal 43 on the Repair: The A5:E2 Aftertreatment Controller is not working
A5:E2 Aftertreatment Controller. properly, replace the A5:E2 Aftertreatment Controller. Pro-
M0070030-01 355
Circuit Tests
Table 248
12. Check the Current Flow to the Heating Element in the ARD 7.0 A and 14 A Result: The current flow is between 7.0 A and 14 A for
Combustion Head for a 12 V a 12 V system. Or, the current flow is between 3.5 A and
System 7 A for a 24 V system.
A. Start the engine. Use a clamp-on ammeter to check the current or The current flow is OK.
flow to the heater. 3.5 A and 7 A
for a 24 V Proceed to Test Step 13.
System
Result: The current flow is not between 7.0 A and 14 A
for a 12 V system. Or, the current flow is not between
3.5 A and 7 A for a 24 V system.
Repair: Repeat the procedure starting with Test Step 4

or Contact the Dealer Solutions Network (DSN).
13. Perform an ARD Fuel Nozzle Heat Cycle Successful Noz- Result: The cycle for the ARD nozzle heater completed
zle Cleaning successfully.
The ECM must have an engine speed signal to initiate the ARD Proceed to Test Step 14.
nozzle heater cycle.

the A5:E2 Aftertreatment Controller. Refer to Troubleshooting,
C. Select the “Diagnostics” tab.
D. Select “Diagnostic Tests” then select “Override Parameters” .
E. Select “Aftertreatment #1 Fuel Injector #1 Heater Override” . Re-

fer to Troubleshooting, “Service Tool Features” for information about
the override.
The cycle for the ARD nozzle heater override will cycle the nozzle
ON and OFF for an hour to clean the nozzle.
14. Perform a Manual DPF Regeneration Successful Result: The service regeneration completes
Manual DPF successfully.
This test must be performed through the electronic service Regeneration
tool. The electronic service tool enhances the diagnostics dur- Return the engine to service.
ing the service test.
A. Perform a “Manual DPF Regeneration” in the electronic service
tool.
The electronic service tool will display a “Waiting On Requirements”

window. The ECM will automatically elevate the engine speed.
The duration of the regeneration depends on the soot load in the

diesel particulate filter. The ECM will automatically return the engine
speed to low idle after the regeneration is complete.
356 M0070030-01
Circuit Tests
i06263906
Coolant Level - Test
Use this procedure to troubleshoot any suspect

problems with the circuit for the coolant level sensor.
The coolant level sensor monitors the engine coolant
level in order to warn the operator when the coolant
level is low.

Components of the coolant level sensor
(1) Sensor
(2) Sensor probe (brass dowel)
(3) Outer coating
When the probe is not immersed in coolant,

approximately +5 VDC is sourced to the sensor
signal wire. When this condition is detected by the
Electronic Control Module (ECM), an event code is
activated.
Prior to troubleshooting any problems with the
coolant level sensor, use the electronic service tool to
check the installation status for the sensor. The
coolant level sensor configuration parameter must be
set to “Installed” in order for the ECM to monitor the
signal from the sensor.
The activation of an event code and/or a warning
lamp is probably caused by a low coolant level. The
next likely cause is a problem with the wiring
harness, a connector, or the sensor.
M0070030-01 357
Circuit Tests
Table 249
1. Check the Coolant Level Coolant level Result: The coolant is at the proper level.
Allow the engine to cool prior to removal of the cooling system Proceed to Test Step 2.
pressure cap.
Result: The coolant level is low.
A. Remove electrical power from the ECM.
Repair: Add coolant according to the procedure in the
B. Check the coolant level. Refer to the Operation and Maintenance Operation and Maintenance Manual.
Manual for the proper procedure to check the coolant level.
There may be a leak in the cooling system. Identify the
source of the coolant leak. Repair the leak. Refer to
Systems Operation/Testing and Adjusting, “Cooling
System” for additional information.
2. Verify that the “ Coolant Level Sensor”” Parameter is Pro- Parameter Result: The “Coolant Level Sensor” parameter is pro-
grammed Correctly programmed grammed correctly.
B. Establish communication with the ECM. Result: The “Coolant Level Sensor” parameter is not
programmed correctly.
C. Verify that the “Coolant Level Sensor” parameter is programmed
to “Installed” . Repair: Program the “Coolant Level Sensor” parame-
ter to “Installed” .
D. Remove electrical power from the ECM.
Verify that the repair eliminates the problem.
358 M0070030-01
Circuit Tests

Terminal locations at the harness connector for the
coolant level sensor
(Terminal A) Sensor supply
(Terminal B) Sensor return
(Terminal C) Sensor signal
Table 250
3. Check the Supply Voltage at the Sensor Connector 8.0 ± 0.5 VDC Result: The voltage measurement is 8.0 ± 0.5 VDC.
A. Disconnect the coolant level sensor at the sensor connector. The supply voltage is reaching the sensor. Proceed to
Test Step 4.
B. Restore electrical power to the ECM.
Result: The voltage measurement is not 8.0 ± 0.5
C. Measure the voltage between terminals A (sensor supply) and B VDC.
(sensor return) at the harness connector for the coolant level sensor. The sensor supply voltage is not reaching the sensor.
There is a problem in the circuit for the sensor supply.
D. Remove electrical power from the ECM.
Repair: Repair the wiring between the sensor and the
ECM.
4. Short the Signal Wire to Ground and Monitor the Status for The voltage is Result: The status changes from “LOW” to “OK” when
“ Coolant Level”” within ±5 VDC of the jumper wire is installed. The ECM and the wiring
battery voltage harness to the coolant level sensor are OK.
A. Fabricate a jumper wire that is long enough to create a short cir-
cuit between two terminals at the coolant level sensor harness con- Repair: Replace the coolant level sensor. Verify that
nector. Crimp connector pins to each end of the jumper wire. the repair eliminates the problem.
B. Install the jumper wire between terminals B (sensor return) and C Result: The status does not change from “LOW” to
(sensor signal) on the harness side of the connector for the coolant “OK” when the jumper wire is installed.
level sensor. The problem is between the ECM and the sensor
connector.
C. Restore electrical power to the ECM.
Repair: Repair the wiring. Verify that the repair elimi-
D. Monitor the status of “Coolant Level” on the electronic service tool nates the problem.
while the jumper wire is installed. Wait at least 30 seconds for activa-
tion of the status indicator.
E. Remove the jumper wire. Connect the harness connector for the
coolant level sensor.
M0070030-01 359
Circuit Tests

steps are listed.
i06677906
Cooling Fan Control - Test
Use this procedure to troubleshoot the electrical

system if a problem is suspected with the engine fan
control solenoid. Use this procedure if one of the
diagnostic codes in Table 251 is active.
Table 251
Code Description Comments
J1939 Code PDL Code
The Electronic Control Module (ECM) de-

tects an open circuit in the circuit for the
Engine Cooling Fan Solenoid : Cur-
4212-5 291-5 engine fan control solenoid.
rent Below Normal
The ECM sends minimum current to the
fan control solenoid. The code is logged.
The ECM detects a short circuit to ground

in the circuit for the engine fan control
Engine Cooling Fan Solenoid : Cur-
4212-6 291-6 solenoid.
rent Above Normal
The Electronic Control Module (ECM) de-

tects an open circuit in the circuit for the
Engine Cooling Fan Bypass Sole-
- 1076-5 engine cooling fan bypass solenoid.
noid : Current Below Normal
The ECM detects a short circuit to ground

in the circuit for the engine cooling fan by-
Engine Cooling Fan Bypass Sole-
- 1076-6 pass solenoid.
noid : Current Above Normal
fan bypass solenoid. The code is logged.
The ECM monitors engine coolant temperature, An override is available with the electronic service
intake manifold air temperature, and hydraulic oil tool. An override allows the fan to be manually
temperature. The ECM monitors the sensors to changed from the minimum to the maximum rpm.
determine the correct speed for the engine cooling
fan.
The ECM controls the speed of the fan by controlling
the current to the engine fan control solenoid. The
engine fan control solenoid controls the amount of
pressure to the fan pump by allowing oil to bypass
the fan pump. The fan pump drives the fan. When the
ECM outputs minimum current to the engine fan
control solenoid, less oil is bypassed. The fan pump
will now drive the fan at a higher rpm. When the ECM
outputs maximum current to the engine fan control
solenoid, more oil is bypassed. The fan pump will
now drive the fan at a lower rpm.
If the ECM detects a system fault, the ECM provides
minimum current to the solenoid. Minimum current
ensures a maximum fan speed when the fault
condition exists.
360 M0070030-01
Circuit Tests

steps are listed.
M0070030-01 361
Circuit Tests
Table 252
1. Check for Active Diagnostic Codes Active Diagnostic Codes Result: No diagnostic codes are active.
A. Remove the electrical power from the ECM.
The problem may have been related to a faulty
B. Verify that the solenoid connector is free of debris and con- connection in the harness. Carefully inspect the
nected securely. connectors and wiring. Refer to Troubleshoot-
ing, “Electrical Connectors - Inspect”.
C. Connect the electronic service tool to the service tool
connector. Result: A short circuit diagnostic code (-6) is
active.
D. Restore the electrical power to the ECM.
E. Select diagnostic tests from the electronic service tool.
Result: An open circuit diagnostic code (-5) is
F. Select the “Override Parameters” screen on the electronic active.
service tool.
G. Activate the fan override.
H. Monitor the active diagnostic code screen on the electronic

service tool. Check and record any active diagnostic codes.
Wait at least 30 seconds in order for the diagnostic code to be-

come active.
I. Disable the fan override.
2. Disconnect the Connector for the Engine Fan Control Short circuit Result: A short circuit diagnostic code (-6) re-
Solenoid in Order to Create an Open Circuit mains active. There is a short circuit between
the harness connector for the engine fan control
A. Remove the electrical power from the ECM. solenoid and the ECM.
B. Disconnect the connector for the engine fan control Repair: Repair the connectors or wiring and/or
solenoid. replace the connectors or wiring. Reset all ac-
tive codes and clear all logged codes. Verify
C. Restore the electrical power to the ECM. that the problem is resolved.
D. Activate the fan override. Result: A short circuit diagnostic code (-6) was
active before disconnecting the connector. An
E. Monitor the active diagnostic code screen on the electronic open circuit diagnostic code (-5) became active
service tool. Check and record any active diagnostic codes. after disconnecting the connector.
Wait at least 30 seconds in order for the diagnostic code to be- Repair: Replace the engine fan control sole-
come active. noid. Reset all active codes and clear all logged
codes. Verify that the problem is resolved.
F. Disable the fan override.
3. Create a Short at the Connector for the Engine Fan Con- Open Circuit Result: The open circuit diagnostic code (-5)
trol Solenoid remains active with the jumper in place.
A. Remove the electrical power from the ECM.
Repair: Repair the connectors or wiring and/or
B. Fabricate a jumper wire that is long enough to create a short replace the connectors or wiring. Reset all ac-
between the terminals of the connector for the engine fan con- tive codes and clear all logged codes. Verify
trol solenoid. Crimp connector pins to each end of the jumper that the problem is resolved.
wire.
Result: A short circuit diagnostic code (-6) is
C. Install the jumper wire between terminal 1 (engine fan con- active when the jumper wire is installed. An
trol solenoid) and terminal 2 (solenoid return) on the harness
side of the connector.
(continued)
362 M0070030-01
Circuit Tests
(Table 252, contd)

open circuit diagnostic code (5) is active when
D. Restore the electrical power to the ECM. the jumper wire is removed.
E. Activate the fan override. Repair: Replace the engine fan control sole-
noid. Reset all active codes and clear all logged
F. Monitor the active diagnostic code screen on the electronic codes. Verify that the problem is resolved.
Wait at least 30 seconds in order for the diagnostic code to be-

come active.
Disable the fan override. Remove the jumper wire.
i06678772
Cooling Fan Reversing - Test
The purpose of a reversing fan is to clean debris from

the radiator. This action is done by temporarily
reversing the direction of the air flow through the
radiator fins to purge the radiator fins. For some
applications, the reversing fan is used to heat the
engine compartment during cold-weather operation.
In the automatic mode, the fan reversing solenoid is
controlled by the engine Electronic Control Module
(ECM). The ECM will automatically reverse the
direction of the fan rotation. The ECM will use a
preset time interval to cycle the fan reversing
solenoid.
The operator can manually reverse the fan rotation
by pressing the engine fan reverse switch. When the
momentary switch is depressed, the direction of the
fan rotation will reverse. Once the switch is allowed to
reset, the fan returns to normal operation and control
of the fan will return to the automatic operation.
Use this procedure to troubleshoot any suspect
problems with the engine fan reverse switch or the
fan reversing solenoid.
Table 253
Description
J1939 Code PDL Code (code descriptions may vary) System Response
Engine Fan Reverse Actuator : This code indicates that there is an open circuit in the engine
4214-5 485-5
Current Below Normal reversing fan solenoid circuit.
Engine Fan Reverse Actuator : This code indicates that there is a short circuit in the engine re-
4214-6 485-6
Current Above Normal versing fan solenoid circuit.
M0070030-01 363
Circuit Tests

steps are listed.
Table 254
1. Determine the Diagnostic Code Active Result: An active or logged -5 code is present.
Codes
A. Establish communication between the electronic service tool and Proceed to Test Step 2.
the engine Electronic Control Module (ECM). Refer to Troubleshoot-
ing, “Electronic Service Tools”, if necessary. Result: An active or logged -6 code is present.

B. Look for an active or logged -5 code or -6 code.
2. Check for an Open Circuit Short Result: A -5 code became active.

Circuit
A. Turn the keyswitch to the OFF position. An open circuit has been detected in the wiring harness.
B. Disconnect the engine reversing fan solenoid connector from the Repair: Repair the wiring or replace the wiring.
wiring harness.
C. Verify that the harness connector is free of debris, free of corro-
sion and was securely connected. Result: A -6 code became active.
D. Connect a jumper wire between the terminals of the harness con- The short circuit was detected by the ECM
nector for the engine reversing fan solenoid. The solenoid coil is re-
placed with a short circuit. Repair: Replace the engine reversing fan solenoid.
E. Turn the keyswitch to the ON position Proceed to Test Step 4.
F. Use the “Engine Reversing Fan Solenoid Override” in the elec-

tronic service tool to turn the solenoid ON.
G. Check for active codes.
(continued)
364 M0070030-01
Circuit Tests
(Table 254, contd)

3. Check for a Short Circuit Open Result: A -5 code became active.

Circuit
A. Turn the keyswitch to the OFF position. The open circuit was detected by the ECM.
B. Disconnect the engine reversing fan solenoid connector from the Repair: Replace the engine reversing fan solenoid.
wiring harness.
sion and was securely connected. Result: A -6 code became active.
D. Turn the keyswitch to the ON position A short circuit has been detected.
E. Check for active codes. Repair: Repair the wiring or replace the wiring.
Result: The engine reversing fan is not operating properly.

4. Check the Engine Reversing Fan Operation Switch
Result: The engine reversing fan is operating properly.
B. Activate the engine reversing fan using the engine reversing fan
switch. Return the unit to service.
5. Check the Engine Reversing Fan Switch Status Result: The switch status changed in the electronic service
Change tool.
A. Disconnect the engine reversing fan solenoid connector from the
wiring harness. A failed engine reversing fan switch has been detected.
B. Use a jumper wire to short circuit the signal and ground wires to- Repair: Replace the engine reversing fan switch.
gether on the harness side of the connector for the switch.
Verify that the problem has been resolved. Return the unit
C. Turn the keyswitch to the ON position to service.
D. Connect to the electronic service tool. Monitor the engine revers- Result: The switch did not change status in the electronic
ing fan switch parameters in the status screen. service tool.
E. Wait at least 30 seconds and check the status of the engine fan A wiring problem between the switch and the ECM has been
reverse switch on the electronic service tool. The correct status for detected.
the switch is ON when the jumper wire is in place.
Repair: Repair or replace the wiring harness between the
F. Remove the jumper wire from the connector. Wait at least 30 sec- switch and the engine harness.
onds and check the status of the engine fan reverse switch on the
electronic service tool. The correct status for the switch is OFF with Verify that the problem has been resolved. Return the unit
the jumper wire removed. to service.
i06891474
Cooling Fan Speed - Test

system if a problem is suspected with the cooling fan
speed sensor. Also use this procedure if the
diagnostic code in Table 255 is active or easily
repeated.
M0070030-01 365
Circuit Tests
Table 255
1639-17 E1363 (1) Low Engine Cooling Fan Speed The code is logged.
Engine Cooling Fan Speed Sensor

N/A 544-2 The code is logged.
: Erratic, Intermittent, or Incorrect
Engine Cooling Fan Speed Sensor

N/A 544-8 : Abnormal Frequency, Pulse The code is logged.
Width, or Period
The engine cooling fan speed sensor provides a

signal to the Electronic Control Module (ECM). The
ECM controls fan speed by varying the current to the
fan control solenoid.
The engine cooling fan speed sensor receives a
supply voltage of 8.0 ± 0.5 VDC from the ECM. The
sensor outputs a frequency that is directly
proportional to fan speed. The sensor generates a
signal pulse for each revolution of the fan. The output
frequency varies between 5 Hz to 180 Hz over the
speed range between 50 rpm and 1800 rpm.

Schematic for the fan speed sensor

steps are listed.
366 M0070030-01
Circuit Tests
Table 256
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 service tool 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”
menu. Proceed to Test Step 2.
E. Start the “Fan Override Test” on the electronic service tool.

Set the fan speed to 500 rpm.
F. Use a T402260 Tachometer Kit 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 the photo-tachometer.
H. Deactivate the “Fan Override Test” .
I. Turn the keyswitch to the OFF position.
(continued)
M0070030-01 367
Circuit Tests
(Table 256, contd)
2. Check the Sensor Supply Voltage at the Sensor Supply Voltage Result: The supply voltage is reaching the sensor.
Connector
Result: The supply voltage is not reaching the sensor.
B. Disconnect the sensor connector from the wiring harness.
Repair: Refer to Troubleshooting, “Sensor Supply - Test”.
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. Note: Large Hydraulic Excavators use a frequency of 27Hz
B. Remove the wire from terminal 1 on the sensor side of the The engine cooling fan speed sensor is generating the correct
connector. Connect the sensor connector. signal.
C. Turn the keyswitch to the ON position. Repair: Repair the harness or replace the harness.
D. Access the “Fan Override Test” under the “Diagnostics” Verify that the problem is resolved.
menu on the electronic service tool.
Note: Large Hydraulic Excavators use a frequency of 27Hz
E. Start the “Fan Override Test” on the electronic service tool.
Set the fan speed to 800 rpm. Result: The frequency is not approximately 80 Hz.
F. Use a multimeter to measure the frequency between the Repair: Replace the fan drive assembly.
signal wire from the sensor and engine ground.
G. Deactivate the “Fan Override Test” .
I. Restore all connectors and wiring to the original

configuration.
i06917820
Data Link - Test
Use this procedure to troubleshoot the Data link

system. Also use this procedure if a diagnostic code
in Table 257 is active or easily repeated.
368 M0070030-01
Circuit Tests
Table 257
Code Description
Communication has been lost to one or more of the devices on the

J1939 Network #1 : Abnormal
639-9 247-9 datalink. If multiple devices are not communicating, there is likely a
Update Rate
problem with the data link wiring, power, or ground circuits.
J1939 Network #1 : Special

639-14 247-14 The affected ECM is missing expected parameters.
Instruction
Update Rate

Instruction
Update Rate

Instruction
The DCU triggered a CAN communication diagnostic code and dis-
Aftertreatment #1 DEF Control- able the SCR system. Troubleshoot and repair the same as a 1235-
3360-9 3820-9
ler : Abnormal Update Rate 9 code, perform an Aftertreatment System Functional Test to verify
the repair
Table 258
J1939 Code PDL Code

5965-5 3838-5
5965-6 3838-6
5966-6 3965-6
If the electronic service tool will not communicate Table 259

with the ECM, refer to Troubleshooting, “Electronic
Electronic Service Tool Diagnostic Code Cross Reference to
Service Tool Does Not Communicate” before you
Wiring Schematic
begin this procedure. The procedure verifies that
electrical power is being supplied to the ECM and to Code Description Data Link
the service tool connector.
J1939 Network #1 Can A
The “Systems Communication Status” is located
under the “Diagnostics” tab in the electronic service J1939 Network #2 Can B
tool. Click the “System Communication Status” J1939 Network #3 Can C
option. Once the screen opens up, the information
will automatically be loaded from the ECM. If there is
an issue with the data link that is repaired, the “Load
from ECM” button must be clicked again for the
updated status. If there are communication issues
between multiple modules, each module can be
selected individually to determine which components
are having communication issues. If the problem is
intermittent, the “View History” button can be clicked
to see all the communication faults that have
previously logged.
M0070030-01 369
Circuit Tests
370 M0070030-01
Circuit Tests
Note: The DEF Quality Sensor is only available on

2017model or later.
-9 Detected Problems:
ECM 1 is unable to communicate on the data link.
• ECM 1 cannot communicate with other ECM's on
the data link, but can communicate with the
service tool. This situation indicates a problem
with the data link wiring.
ECM 1 is unable to communicate with ECM 2 on
the data link.
• ECM 1 cannot communicate with ECM 2,
indicating a problem with the data link wiring,
power or ground circuit, or ECM 2.
-14 Detected Problems:
ECM 1 is unable to obtain a network address on
the data link.
• ECM 1 is trying to claim the same address as
another ECM. An example of this situation is 2
ECM's being configured the same.
ECM 1 detects a failed address claim from ECM 2
on the data link.
• ECM 1 detects that ECM 2 is trying to claim the

same address as another ECM.
ECM 1 is not receiving all expected parameters
from ECM 2 on the data link.
• A component is configured as installed in the
ECM, but is not installed on the application.
• The incorrect component is installed.
• The incorrect software file has been installed.

steps are listed.
M0070030-01 371
Circuit Tests
Table 260
1. Check for Associated Diagnostic Trouble Codes Associated Result: An associated diagnostic trouble code is not ac-
Codes tive or logged.
and the ECM. Refer to Troubleshooting, “Electronic Service Proceed to Test Step 2.
Repair: Troubleshoot the associated codes before con-
tinuing with this procedure.
Refer to Troubleshooting, “Diagnostic Trouble Codes” to

troubleshoot the associated diagnostic code.
2. Use the “ System Communication Status”” to Determine the Component Result: A -9 code is active.
Communication Issue Identified
Repair: Refer to the above -9 detected problems for
A. In the electronic service tool, click the “Diagnostics” tab on the more information.
tool bar.
B. Select the “System Communication Status” option from the
drop-down list. Result: A -14 code is active.
Note: The Aftertreatment #1 Intake NOx Level Sensor is dis- Refer to the above -14 detected problems for more
played as Aftertreatment #1 Information #1 in some versions of information.
software.
If the NOx sensors are listed as ECM 2, Proceed to Test
Step 3.
For all other components, Proceed to Test Step 4.
3. Check the Part Number of the Component Part Number Result: The part number is correct for the application.
A. Locate the part number of the component that was identified by Proceed to Test Step 4.
the “System Communication Status” . Check to see if the part
number is correct for the application. Result: The part number is incorrect for the application.
Repair: Replace the component with the correct part

number.
procedure.
(continued)
372 M0070030-01
Circuit Tests
(Table 260, contd)

4. Check the Programmable Parameters Configuration Result: The components are configured correctly.
A. Navigate to the configuration screen in the electronic service Proceed to Test Step 5.
tool.
Result: The components are not configured correctly.
B. Identify the component that logged the -14 code.
Repair: Configure the components properly for the
C. Determine if the component is configured correctly for the application.
application.
5. Check the Software Flash File (if applicable) Flash File Result: The flash file is correct for the application.
A. Check the flash file part number to make sure that the file Repair: A failed component has been identified. Replace
matches the most current revision. the failed component.
Result: The flash file is incorrect for the application.
Repair: Reflash the component to the correct flash file.

ECM 1 present
(1) Column 1
M0070030-01 373
Circuit Tests

ECM 1 and ECM 2 present
(1) Column 1 (3) ECM 2 is the affected ECM/device that
(2) Multiple ECM 1 and ECM 2 can be cannot be recognized by ECM 1. ECM 2
displayed is the ECM/device with the problem.
374 M0070030-01
Circuit Tests
Table 261
6. Use the System Communication Status to Determine the Component Result: ECM 1 and ECM 2 are both present.
Cause Identified
Record the devices identified as ECM 1 and ECM 2 in
A. Determine if both ECM 1 and ECM 2 are present in the “ECMs” column 1.
column (1) within the “System Communication Status” screen. Re-
fer to Illustration 133 . Refer to Illustration 133 .
Note: The Aftertreatment #1 Intake NOx Level Sensor is dis- Proceed to Test Step 7.
played as Aftertreatment #1 Information #1 in some versions of
software. Result: Only ECM 1 is present.
Record the device identified as ECM 1 in column 1.
Refer to Illustration 132 .
7. Check the Resistance of the Data link 60+/-10 Ohms Result: The resistance is less than 50 Ohms.
A. Turn the keyswitch to the OFF position. There are more than 2 terminating resistors installed in
the wiring harness or a short circuit has been detected.
B. Measure the resistance of the datalink between ECM 2 datalink
(+) wire and the datalink (-) wire on the wiring harness connector Repair: Repair or replace parts as necessary.
of ECM 2. Refer to the appropriate wiring diagram.
Note: If ECM 2 is the Aftertreatment Diesel Exhaust Fluid Control-
ler (DCU), the T400243 Break-out Connector must be used to Result: The resistance is 60 ±10 Ohms.
prevent damage to the DCU connector.
The terminating resistors are OK.
Result: The resistance is 120 ±10 Ohms.
There is a problem with a terminating resistor.
Repair: Check the resistance on each terminating resis-

tor. Replace the failed terminating resistor.
Result: The resistance is greater than 130 Ohms.
There is a problem with both terminating resistors or an

open circuit has been detected.
Repair: Determine the cause of the problem. Repair the

problem, when possible. Replace parts, if necessary. Ver-
(continued)
M0070030-01 375
Circuit Tests
(Table 261, contd)

Result: The voltage is not equal to battery voltage.
8. Check the Power and Ground to ECM 2 Battery Voltage
There is an open or short in the wiring circuit. Repair or
A. Turn the keyswitch to the ON position. replace the wiring circuit as necessary. Refer to the appli-
cation schematic for wiring information.
B. Measure the voltage between the battery (+) and battery (-) ter-
minals on the wiring harness connector of ECM 2. Refer to the ap- Proceed to Test Step 11.
propriate wiring diagram.
Result: The voltage is equal to battery voltage and ECM
Note: If ECM 2 is the DCU, the T400243 Break-out Connector 2 is NOT the DCU.
must be used to prevent damage to the DCU connector.
Repair: Replace the component identified as ECM 2.
procedure.
Result: The voltage is equal to battery voltage and ECM

2 is the DCU.
9. Check the Resistance of the Data Link 60+/-10 Ohms Result: The resistance is less than 50 Ohms.
A. Turn the keyswitch to the OFF position. There are more than 2 terminating resistors installed in
the wiring harness or a short circuit has been detected.
B. Measure the resistance of the data link between ECM 1 data
link (+) wire and the data link (-) wire on the wiring harness con- Repair: Repair or replace parts as necessary.
nector of ECM 1. Refer to the appropriate wiring diagram.
Note: If measuring at the DCU wiring harness connector, the
T400243 Break-out Connector must be used to prevent damage Result: The resistance is 60 ±10 Ohms.
to the DCU connector.
The terminating resistors are OK.
Check the power, ground, and keyswitch (if applicable)

supply to each module on the affected data link. Refer to
the appropriate wiring diagram.
Note: Keyswitch must be in the ON position when

checking the power supply.
Repair the power or ground supply to the modules if

necessary.
Result: The resistance is 120 ±10 Ohms.
There is a problem with a terminating resistor. Check the

resistance on each terminating resistor.
Repair: Replace the failed terminating resistor.
Result: The resistance is greater than 130 Ohms.
(continued)
376 M0070030-01
Circuit Tests
(Table 261, contd)

There is a problem with the wiring harness between ECM
1 and the splice point into the data link wiring. Refer to
the appropriate wiring diagram.
Repair: Determine the cause of the problem. Repair the

problem, when possible. Replace parts, if necessary. Ver-
10. Check the Keyswitch Circuit to the DCU Battery Voltage Result: The voltage is equal to battery voltage.
A. Turn the keyswitch to the OFF position. Repair: Replace the DCU.
B. Disconnect the 53-pin connector from the DCU. Proceed to Test Step 11.
C. Connect the T400243 Break-out Connector to pin 52 at the Result: The voltage is not equal to battery voltage.
DCU connector.
Repair: There is an open circuit or a short circuit in the
The connectors must be used to prevent damage to the DCU keyswitch wiring circuit. Repair or replace the wiring cir-
connector. cuit as necessary. Refer to Troubleshooting, “DEF Con-
trol Module Power - Test”.
E. Measure the voltage between keyswitch power (pin 52) and a

known good ground source.
11. Use the “ Systems Communication Status”” to Determine Component Result: The “Systems Communication Status” does not
the Communication Issue Identified show any communication issues.
A. In the electronic service tool, click the “Diagnostics” tab on the Return the unit to service.
tool bar.
Result: The datalink health monitor shows that there are
B. Select the “System Communication Status” option from the devices that are not communicating.
drop-down list.
Contact the Dealer Solutions Network (DSN) for
C. Click the “Load from ECM” button to determine if any devices assistance.
are not communicating.
i06679609 Use this procedure to troubleshoot a diagnostic code

for a special instruction. Use this procedure if one of
Data Link Configuration Status the following diagnostic codes are active.
- Test Note: Some of the following codes may not be
The diagnostic code for the special instruction is

logged to report the configuration status of the data
link.
• The configuration of parameter is invalid.

• Incorrect module or display on the data link
• The engine ECM or the aftertreatment ECM is

flashed with software that is incompatible with the
software on the other ECM
M0070030-01 377
Circuit Tests
Table 262
Code Description
625-14 246-14 Proprietary Data Link : Special Instruction The code is logged.
Aftertreatment #1 Identification Number Mod-

5576-14 3468-14 The code is logged.
ule : Special Instruction
Aftertreatment #2 Identification : Special

Instruction
5588-14 E1132 (2) Proprietary Network #2 : Special Instruction The code is logged.
Table 263
J1939 Code PDL Code

639-9 247-9
639-14 247-14
1231-9 2348-9
1231-14 2348-14
1235-9 5856-9
1235-14 5856-14

steps are listed.
378 M0070030-01
Circuit Tests
Table 264
1. Check for an Associated Code Associated Result: An associated -9 or -14 code is active or logged.
Trouble Code
A. Establish communication between the electronic service tool Repair: Repair all associated -9 or -14 codes before con-
and the Electronic Control Module (ECM) for the engine. tinuing with this procedure. Refer to Troubleshooting,
“Data Link - Test”.
Result: A 3468-14, 3469-14, 5576-14, or 5577-14 code
is active or logged.
Result: A 246-14, 625-14, 5588 -14, or E1132 (2) code

is active or logged.
2. Check the Configuration Parameters Serial Number Result: The CEM serial number matches the “Factory
Installed Aftertreatment Identification Number” .
A. Check the Clean Emissions Module (CEM) serial number on
the CEM data plate. Repair: Replace the Aftertreatment Identification
module.
B. Connect to the electronic service tool.
C. Connect to the “Engine #1 Aftertreatment Controller” . Under
“Aftertreatment Configuration” in the Configuration Parameters, Result: The CEM serial number does not match the
make sure that the “Factory Installed Aftertreatment Identification “Factory Installed Aftertreatment Identification Number” .
Number” matches the CEM serial number.
Repair: Verify that the correct CEM is installed on the en-
gine. Program the CEM serial number into the “Factory
Installed Aftertreatment Identification Number” .
3. Check the Software in the “ Engine #1 Aftertreatment Compatible Result: The software updated successfully and the code
Controller”” Software changed to logged.
A. Update the software in the “Engine #1 Aftertreatment Control- Return the unit to service.
ler” .
Note: This code indicates that the software in the Engine ECM
and the “Engine #1 Aftertreatment Controller” do not match. If the
software in one ECM was updated, and the other was not, this
code will log.
M0070030-01 379
Circuit Tests
i06679832
DEF Control Module Power - Test
Table 265

PDL Code Comments
Code
An open circuit has been detected on the keyswitch circuit between the A5:E2
5966-5 3965-5 Fluid Control Module Power
aftertreatment controller and the DCU.
Supply : Current Below Normal

A short circuit has been detected on the keyswitch circuit between the A5:E2 after-
5966-6 3965-6 Fluid Control Module Power
treatment controller and the DCU.
Supply : Current Above Normal
Aftertreatment #1 Diesel Ex-

haust Fluid Control Module Pin 29 of the A5:E2 aftertreatment controller has a short circuit to battery positive
6309-6 3966-6
Power Supply #2 : Current or negative.
Above Normal
380 M0070030-01
Circuit Tests

steps are listed.
M0070030-01 381
Circuit Tests
Table 266
1. Determine the Code Diagnostic Trou- Result: A 3965-5 or 5966-5 code is active.
ble Code
and the Electronic Control Module (ECM). Refer to Troubleshoot-
ing, “Electronic Service Tools”, if necessary. Result: A 3965-6 or 5966-6 code is active.
B. Determine the diagnostic trouble code that is active. Proceed to Test Step 3.
Result: A 3966-6 or 6309-6 code is active.
2. Check the Wiring for an Open Circuit Diagnostic Trou- Result: 3965-5 or 5966-5 and 1235-9 or a 5856-9 codes
ble Code are both active at the same time.
A. Turn the keyswitch to the OFF position for 2 minutes. The key-
switch must be off for 2 minutes to allow the DEF pump to purge, An open circuit has been detected between the 12-pin
to reset the code, and to reset the DCU. PETU harness connector and the DCU harness 53-pin
connector.
B. Disconnect the 12-pin PETU harness connector. Verify that the
harness connector is free of debris, corrosion and securely Repair: Replace the PETU wiring harness.
connected.
Verify that the problem is resolved. Return the unit to
C. Install a jumper wire between pin 5 on the 12-pin connector on service.
the A5:E2 aftertreatment controller side and a known good
ground. Result: A 1235-9 or 5856-9 code is active.
D. Turn the keyswitch to the ON position. An open circuit has been detected between the A5:E2
Aftertreatment Controller and the 12-pin PETU harness
E. Check for an active code. connector.

service.
(continued)
382 M0070030-01
Circuit Tests
(Table 266, contd)

3. Check the DCU Wiring for a Short Circuit Diagnostic Trou- Result: 3965-6 or 5966-6 and 1235-9 or 5856-9 codes
ble Code are both active at the same time.
switch must be off for 2 minutes to allow the DEF pump to purge, A short circuit has been detected between the A5:E2
to reset the code, and to reset the DCU. Aftertreatment Controller and the 12-pin PETU harness
connector.
harness connector is free of debris, corrosion and securely Repair: Repair or replace the wiring harness.
connected.
C. Turn the keyswitch to the ON position. service.
D. Check for an active code. Result: A 1235-9 or 5856-9 code is active.
A short circuit has been detected between the 12-pin PE-

TU harness connector and the DCU harness 53-pin
connector.
Repair: Repair or replace the PETU wiring harness.

service.
4. Check the DCU Keyswitch Wiring for a Short Circuit to Short Circuit Result: There is less than 100k ohm of resistance be-
Ground tween pin 29 and ground.
A. Turn the keyswitch to the OFF position for 2 minutes. The key- A short circuit has been detected between pin 29 and
switch must be off for 2 minutes to allow the DEF pump to purge, ground.
to reset the code, and to reset the DCU.
harness connector is free of debris, and corrosion. Verify that the problem is resolved. Return the unit to
service.
C. Disconnect the J1 connector on the A5:E2 aftertreatment con-
troller. Measure the resistance between pin 29 and a known good Result: There is more than 100k ohm of resistance be-
ground. tween pin 29 and ground.
5. Check the DCU Keyswitch Wiring for a Pin to Pin Short Short Circuit Result: There is less than 100k ohm of resistance be-
Circuit tween pin 29 and any other pin in the J1 connector ex-
cept pin 10.
switch must be off for 2 minutes to allow the DEF pump to purge, A short circuit has been detected.
to reset the code, and to reset the DCU.
harness connector is free of debris, and corrosion. Verify that the problem is resolved. Return the unit to
service.
C. Disconnect the J1 connector on the A5:E2 aftertreatment con-
troller. Measure the resistance between pin 29 and all other pins in Result: There is more than 100k ohm of resistance be-
the 70-pin connector. tween pin 29 and all other pins in the J1 connector except
Note: There should be continuity between pins 10 and 29 pin 10.
only.
Inspect the wiring for an intermittent short.
(continued)
M0070030-01 383
Circuit Tests
(Table 266, contd)


service.
i06681484
DEF Line Heater - Test
The applicable ECM sets a diagnostic trouble code if

the current flow through a coil is incorrect. These
codes can be activated only when the applicable
ECM is sending a command to the coil. 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.
Table 267 lists the diagnostic codes for incorrect
current flow.
Table 267
Code Description
PDL Code Comments
Code vary)
4354-5 3110-5 Fluid Line Heater 1 : Current Be- This code indicates that there is a problem with the Backflow/Return line heater
low Normal
4354-6 3110-6 Fluid Line Heater 1 : Current This code indicates that there is a problem with the Backflow/Return line heater
Above Normal

4355-5 3111-5 Fluid Line Heater 2 : Current Be- This code indicates that there is a problem with the Pressure/Injector line heater
low Normal

4355-6 3111-6 Fluid Line Heater 2 : Current This code indicates that there is a problem with the Pressure/Injector line heater
Above Normal
4356-5 3112-5 Fluid Line Heater 3 : Current Be- This code indicates that there is a problem with the Supply/Suction line heater
low Normal
4356-6 3112-6 Fluid Line Heater 3: Current This code indicates that there is a problem with the Supply/Suction line heater
Above Normal
(continued)
384 M0070030-01
Circuit Tests
(Table 267, contd)

Code Description
PDL Code Comments
Code vary)
5491-5 3822-5 Fluid Line Heater Relay: Current This code indicates that there is a problem with the line heater relay.
Below Normal
5491-6 3822-6 Fluid Line Heater Relay: Current This code indicates that there is a problem with the line heater relay.
Above Normal
Note: Refer to Troubleshooting, “Component

Location” in this manual for the proper location of the
components listed in this procedure.
M0070030-01 385
Circuit Tests
(1) Coolant Supply Fitting (5) Suction Line (Line Heater #3) (9) DEF Header Connector
(2) Line Heater #1 Connector (6) DEF Header (10) Coolant Return Fitting
(3) Line Heater #3 Connector (7) Backflow Line (Line heater #1) (11) Pressure Line Connection (Line Heater
(4) Coolant Supply to DEF Header (8) Coolant Supply to DEF Pump #2)
386 M0070030-01
Circuit Tests
(12) Line heater relay (13) Main power relay
M0070030-01 387
Circuit Tests

Not all connectors are shown, refer to the appropriate schematic
388 M0070030-01
Circuit Tests
M0070030-01 389
Circuit Tests
Table 268
Associated Codes
J1939 Code PDL Code
3363-5 3126-5
3363-6 3126-6

steps are listed.
Table 269
1. Determine the Diagnostic Code Diagnostic Result: There is an associated code active or logged.
Trouble
A. Establish communication between the electronic service tool Codes Repair: Troubleshoot the associated codes. Refer to Trou-
and the engine Electronic Control Module (ECM) . Refer to Trou- bleshooting, “Diagnostic Trouble Codes or Event Codes” for
bleshooting, “Electronic Service Tools”, if necessary. the proper procedure.
B. Establish communication between the electronic service tool Result: There is an active or there is a logged -5 code other
and the Diesel Exhaust Fluid Controller (DCU) . than a 3822-5 or 5491-5 code.
C. Look for an active or logged -5 code or -6 code. Proceed to Test Step 2.
Result: There is an active or there is a logged 3822-5 or

5491-5 code.
Result: There is an active or there is a logged -6 code.
2. Check for Power at Aftertreatment 1 Diesel Exhaust Fluid Battery Result: The voltage between terminal 1 and a good ground
Line Heater Relay Voltage source is equal to battery voltage.
A. Turn the keyswitch to the OFF position. Allow 2 minutes to Turn the keyswitch to the OFF position. Allow 2 minutes to
elapse before proceeding. elapse, reinstall the relay. Proceed to Test Step 3.
B. Remove the heated line relay from the harness. Result: The voltage between terminal 1 and a good ground
source is not equal to battery voltage.
C. Verify that the harness connector is free of debris and free of
corrosion. Repair: Refer to the schematic and troubleshoot the power
source from the VLPM.
E. Check for battery voltage between terminal 1 of the heated line

relay and a known good ground .
(continued)
390 M0070030-01
Circuit Tests
(Table 269, contd)

3. Check the Wiring for an Open Circuit Short Circuit Result: A -5 code became active during the electrical
checkout.
A. Disconnect the suspect line heater from the aftertreatment
harness. The DCU did not detect the jumper wire. There is an open
circuit between the heated line relay and the DCU connector.
B. Verify that the harness connector is free of debris, free of corro-
sion and securely connected. Repair: Turn the keyswitch to the OFF position. Allow 2 mi-
nutes to elapse, replace the heated line relay.
C. Connect a jumper wire between the terminals of the harness
connector for the suspect heated line. The heated line is replaced Proceed to Test Step 4.
with a short circuit.
Result: A -6 code is activated during the electrical checkout.
D. Turn the keyswitch to the ON position. The DCU detected the jumper wire. There is a problem with
the heated line.
E. Connect to the “Diesel Exhaust Fluid Controller #1” ECM using
the electronic service tool. Repair: Replace the heated line.
F. Go to “Diagnostic Tests” and perform a “DEF Heated Line Test” Turn the keyswitch to the off position for 2 minutes. The key-
. switch must be off for 2 minutes to allow the DEF pump to
purge, to reset the code, and to reset the DCU.
Perform a “DEF Heated Line Test” to verify the repair. Return

4. Check the Wiring for an Open Circuit Short Circuit Result: A -5 code became active during the electrical
checkout.
elapse before proceeding. The DCU did not detect the jumper wire. There is an open
circuit between the heated line relay and the DCU connector.
B. Disconnect the suspect line heater or heated line relay from the There may be a problem with a connector.
aftertreatment harness.
Repair: Replace the harness.
C. Connect a jumper wire between the terminals of the harness
connector for the suspect heated line or heated line relay coil (Pin Turn the keyswitch to the off position for 2 minutes. The key-
2 and Pin 5). The heated line or coil is replaced with a short circuit. switch must be off for 2 minutes to allow the DEF pump to
E. Connect to the “Diesel Exhaust Fluid Controller #1” ECM using the unit to service.
Result: A -6 code became active during the electrical
F. Go to “Diagnostic Tests” and perform a “DEF Heated Line Test” checkout.
.
The DCU detected the jumper wire. There is a problem with
the heated line relay.
Repair: Replace the heated line relay.
Turn the keyswitch to the off position for 2 minutes. The key-
switch must be off for 2 minutes to allow the DEF pump to

M0070030-01 391
Circuit Tests
Table 270
5. Check the Wiring for a Short Circuit Open Circuit Result: A -6 code became active during the electrical
checkout.
elapse before proceeding. The DCU did not detect the open circuit. There is a short cir-
cuit in the wiring between the heated line or heated line relay
B. Disconnect the heated line or heated line relay from the after- coil and the DCU connector. There may be a problem with a
treatment harness. connector.
C. Verify that the harness connector is free of debris, free of corro- Repair: Replace the harness.
sion and securely connected.
Turn the keyswitch to the OFF position for 2 minutes. The
D. Turn the keyswitch to the ON position. keyswitch must be off for 2 minutes to allow the DEF pump
to purge, to reset the code, and to reset the DCU.
E. Connect to the “Diesel Exhaust Fluid Controller #1” ECM using
the electronic service tool. Perform a “DEF Heated Line Test” to verify the repair. Return
F. Go to “Diagnostic Tests” and perform a “DEF Heated Line Test”
. Result: A -5 code is activated during the electrical checkout.
The DCU detected the open circuit. There is a problem with
the heated line or heated line relay coil.
Repair: Replace the heated line or heated line relay.
Turn the keyswitch to the off position for 2 minutes. The key-
switch must be off for 2 minutes to allow the DEF pump to


i06920089
DEF Pump Motor - Test
Table 271 lists the diagnostic codes for the Diesel

Exhaust Fluid (DEF) pump circuit.
Table 271
Code Description
PDL Code Comments
Code vary)
Aftertreatment #1 Diesel Exhaust
This code indicates that there is problem with the DEF pump or the wiring
4374-5 3118-5 Fluid Pump Motor Speed : Cur-
harness.
rent Below Normal
Aftertreatment #1 Diesel Exhaust
This code indicates that there is problem with the DEF pump or the wiring
4374-6 3118-6 Fluid Pump Motor Speed : Cur-
harness.
rent Above Normal
392 M0070030-01
Circuit Tests
Table 272
Required Tools
A T4000242 Break-out Connector 1

B T4000243 Break-out Connector 1
Table 273
Associated Codes
J1939 Code PDL Code Code Description
Aftertreatment #1 DEF Temperature #1 Sen-
4337-8 3096-8 sor : Abnormal Frequency, Pulse Width, or
Period

steps are listed.
M0070030-01 393
Circuit Tests
Table 274
1. Check for Diagnostic Codes Diagnostic codes Result: An associated code is present.
A. Turn the keyswitch to the ON position. Refer to Troubleshooting, Diagnostic Trouble

Codes.
B. Connect the electronic service tool.
Result: A 3118 (4374) code is present.
C. Record the diagnostic codes.
2. Check for Opens in the Pump Electronic Tank Unit (PETU) Open Circuit Result: There were less than 10 Ohms of resist-
Wiring Harness for the DEF Pump Motor Circuit ance on all the DEF pump motor circuit wires.
A. Turn the keyswitch to the “OFF” position. The keyswitch must Proceed to Test Step 3.
be OFF for 2 minutes to allow the DEF pump to purge, reset the
code, and reset the DCU. Result: There were more than 10 Ohms of resist-
ance on any one of the DEF pump motor circuit
B. Disconnect the PETU wiring harness from the DEF pump and wires.
the Diesel Exhaust Fluid Controller (DCU).
Repair: There is an open in the harness. Repair
C. Connect Tooling (B) to the DCU connector. the wiring or replace the harness.
Connect Tooling (A) to the pump connector.
The connectors must be used to prevent damage to the DCU Verify that the problem is resolved.
and pump connectors.
D. Measure the resistance between terminal 9 (PWM +) on the
DEF pump connector and terminal 46 (PWM +) on the 86-pin
DCU connector.
E. Measure the resistance between terminal 8 (PWM -) on the

DEF pump connector and terminal 26 (PWM -) on the 86-pin DCU
connector.
F. Measure the resistance between terminal 10 (PWM SIGNAL)

on the DEF pump connector and terminal 24 (PWM SIGNAL) on
the 86-pin DCU connector.
(continued)
394 M0070030-01
Circuit Tests
(Table 274, contd)

3. Check for Short Circuits in the PETU Wiring Harness for Short Circuit Result: There were more than 100 K Ohms of re-
the DEF Pump Motor Circuit sistance between the connector terminal and
ground on all the DEF pump motor circuit wires.
A. Turn the keyswitch to the “OFF” position. The keyswitch must
be OFF for 2 minutes to allow the DEF pump to purge, reset the Proceed to Test Step 4.
code, and reset the DCU.
Result: There were less than 100 K Ohms of re-
B. Disconnect the PETU wiring harness from the DEF pump and sistance between the connector terminal and
the DCU. ground on any one of the DEF pump motor circuit
wires.
C. Connect Tooling (B) to the DCU connector.
Connect the Tooling (A) to the pump connector. Repair: There is a short circuit in the harness.
The connectors must be used to prevent damage to the DCU Repair the wiring or replace the harness.
and pump connectors.
D. Measure the resistance between terminal 9 (PWM +) on the
DEF pump connector and a known good chassis ground. Proceed to Test Step 5.
E. Measure the resistance between terminal 8 (PWM -) on the

DEF pump connector and a known good chassis ground.

on the DEF pump connector and a known good chassis ground.
the DEF Pump Motor Wiring sistance on all the DEF pump motor circuit wires.
A. Turn the keyswitch to the “OFF” position. The keyswitch must Repair: A failed DEF pump has been detected.
be OFF for 2 minutes to allow the DEF pump to purge, reset the Replace the DEF pump.
code, and reset the DCU.
B. Disconnect the PETU wiring harness from the DEF pump and
the DCU. Result: There were less than 100 K Ohms of re-
sistance on any one of the DEF pump motor cir-
C. Connect Tooling (B) to the DCU connector. cuit wires.
Tooling (B) must be used to prevent damage to the DCU
connector. Repair: There is a short circuit in the harness.
Repair the wiring or replace the harness.
D. Measure the resistance between terminal 46 (PWM +) and all
other pins in the 86-pin DCU harness connector. Verify that the problem is resolved.
E. Measure the resistance between terminal 26 (PWM -) and all Proceed to Test Step 5.
other pins in the 86-pin DCU harness connector.

and all other pins in the 86-pin DCU harness connector.
5. Perform a DEF Dosing System Verification Test Diagnostic Codes Result: The code did not return.
A. Turn the keyswitch to the “ON” position. Do not start the Return the unit to service.
engine.
B. Connect to the “Diesel Exhaust Fluid Controller #1 ECM” using

C. Perform the “DEF Dosing System Verification Test” .
M0070030-01 395
Circuit Tests
i06681608
DEF Pump Pressure Sensor -

Test

Table 275

PDL Code Comments
Code
There is excessive voltage on the signal wire between the Diesel Exhaust Fluid
Controller (DCU) and the DEF pump or there is an open circuit on the supply, sig-
nal, 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
4334-4 3090-4 Fluid Doser Absolute Pressure : pressure sensor.
Voltage Below Normal The code is logged.
Table 276
Required Tools
Tool Part Number Part Qty

Description
A T400242 Break-out 1
Connector
B T400243 Break-out 1
Connector

steps are listed.
396 M0070030-01
Circuit Tests
Table 277
1. Check for Opens in the Pump Electronic Tank Unit (PETU) Open Circuit Result: There were less than 10 Ohms of resist-
Wiring Harness for the DEF Pump Pressure Sensor Circuit ance on all the DEF pump pressure circuit wires.
A. Turn the keyswitch to the OFF position for 2 minutes. The key- Proceed to Test Step 2.
switch must be OFF for 2 minutes to allow the DEF pump to
purge, reset the code, and reset the Diesel Exhaust Fluid Control- Result: There were more than 10 Ohms of resist-
ler (DCU). ance on any one of the DEF pump pressure cir-
cuit wires.
B. Disconnect the PETU wiring harness from the DEF pump and
the DCU. Repair: There is an open in the harness. Repair
the wiring or replace the harness.
C. Connect Tooling (B) to the DCU connector. Connect Tooling
(A) to the DEF pump connector. Verify that the problem is resolved.
The connectors must be used to prevent damage to the DCU
and DEF pump connector. Proceed to Test Step 4.
D. Measure the resistance between terminal 2 (SUPPLY) on the

DEF pump connector and terminal 19 (SUPPLY) on the 86-pin
DCU connector.
E. Measure the resistance between terminal 3 (SIGNAL) on the

DEF pump connector and terminal 17 (SIGNAL) on the 86-pin
DCU connector.
F. Measure the resistance between terminal 4 (GROUND) on the

DEF pump connector and terminal 18 (GROUND) on the 86-pin
DCU connector.
the DEF Pump Pressure Sensor Circuit sistance between the connector terminal and
ground on all the DEF pump pressure circuit
A. Turn the keyswitch to the “OFF” position. wires.
B. Disconnect the PETU wiring harness from the DEF pump and Proceed to Test Step 3.
the DCU.
Result: There were less than 100 K Ohms of re-
C. Connect Tooling (A) to the DEF pump connector. sistance between the connector terminal and
The connector must be used to prevent damage to the DEF ground on any one of the DEF pump pressure cir-
pump connector. cuit wires.
D. Measure the resistance between terminal 2 (SUPPLY) on the Repair: There is a short circuit in the harness.
DEF pump connector and a known good chassis ground. Repair the wiring or replace the harness.
E. Measure the resistance between terminal 3 (SIGNAL) on the Verify that the problem is resolved.
F. Measure the resistance between terminal 4 (GROUND) on the
(continued)
M0070030-01 397
Circuit Tests
(Table 277, contd)

the DEF Pump Pressure Sensor Circuit sistance on all the DEF pump pressure circuit
wires.
A. Turn the keyswitch to the “OFF” position.
Repair: A failed DEF pump has been detected.
B. Disconnect the PETU wiring harness from the DEF pump and Replace the DEF pump.
the DCU.
C. Connect Tooling (B) to the DCU connector.
Tooling (B) must be used to prevent damage to the DCU Result: There were less than 100 K Ohms of re-
connector. sistance on any one of the DEF pump pressure
circuit wires.
D. Measure the resistance between terminal 19 (SUPPLY) of the
DCU connector and all other pins in the 86-pin DCU harness Repair: There is a short circuit in the harness.
connector. Repair the wiring or replace the harness.
E. Measure the resistance between terminal 17 (SIGNAL) of the Verify that the problem is resolved.
DCU connector and all other pins in the 86-pin DCU harness
F. Measure the resistance between terminal 18 (GROUND) of the

DCU connector and all other pins in the 86-pin DCU harness
connector.
Diagnostic Codes
4. Perform a DEF Dosing System Verification Test Result: The code did not return.
engine.

i06681648
DEF Pump Sensor Supply -

Test

Table 278

PDL Code Comments
Code
Sensor Supply #3:Other Failure High or low battery voltage supply has been detected on the 5V supply to the
3511-11 3482-11
Mode DEF pump.
398 M0070030-01
Circuit Tests

steps are listed.
Table 279
Required Tools
A T40-0242 Break-out 1
Connector
B T40-0243 Break-out 1
Connector
M0070030-01 399
Circuit Tests
Table 280
1. Check the DEF Pump Pressure Sensor Supply Circuit for Supply Voltage Result: The voltage is greater than 5V.
Excessive Voltage
switch must be OFF for 2 minutes to allow the DEF pump to Result: The voltage is 5V or less.
purge, reset the code, and reset the Diesel Exhaust Fluid Control-
ler (DCU). Proceed to Test Step 2.
B. Disconnect the Pump Electronic Tank Unit (PETU) harness

from the DEF pump.

sion, and securely connected.
D. Turn the keyswitch ON.
E. Measure the voltage between the 5V SUPPLY (Terminal 2) at

the DEF pump connector and a known good ground source.
2. Check the DEF Pump Pressure Sensor Supply for a Short Short Circuit Result: There were more than 100K ohms of re-
Circuit to Ground sistance between the 5V SUPPLY and a ground
source.
switch must be OFF for 2 minutes to allow the DEF pump to Proceed to Test Step 4.
purge, reset the code, and reset the DCU.
Result: There were less than 100K ohms of re-
B. Disconnect the PETU wiring harness from the DEF pump. sistance between the 5V SUPPLY and a ground
source.
C. Disconnect the 86-pin connector from the DCU.
Repair: A short circuit to ground has been de-
D. Connect Tooling (A) to the DEF pump connector. tected. Repair or replace the wiring harness.
Tooling (A) must be used to prevent damage to the DEF
pump connector. Proceed to Test Step 4.
E. Measure the resistance between the 5V SUPPLY (Terminal 2

at the DEF pump connector) and a known good ground source.
(continued)
400 M0070030-01
Circuit Tests
(Table 280, contd)

3. Check the DEF Pump Supply for a Pin-to Pin Short Circuit Short Circuit Result: There were more than 100K ohms of re-
sistance between the 5V SUPPLY and all other
A. Turn the keyswitch to the OFF position for 2 minutes. The key- pins in the DEF pump connector.
switch must be OFF for 2 minutes to allow the DEF pump to
purge, reset the code, and reset the DCU. Proceed to Test Step 4.
B. Disconnect the PETU wiring harness from the DEF pump. Result: There were less than 100K ohms of re-
sistance between the 5V Supply and all other
C. Disconnect the 86-pin connector from the DCU. pins in the DEF pump connector.
D. Connect Tooling (B) to the DCU connector. Repair: There is a problem in the wiring harness.
Tooling (B) must be used to prevent damage to the DCU Repair or replace the wiring harness.
connector.
E. Measure the resistance between the 5V SUPPLY (Terminal 19
at the DCU connector) and all other pins in the DCU 86-pin
connector.
4. Perform a DEF Dosing System Verification Test Diagnostic Codes Result: The code did not return.
engine.
Result: The code returned.
the electronic service tool. Repair: A failed DEF pump has been detected.
Replace the DEF pump.
Perform the DEF Dosing Verification Test to verify
that the issue has been resolved.
i06682584
DEF Return Valve - Test

Exhaust Fluid (DEF) pump reverting valve circuit.
Table 281

PDL Code Comments
Code
This code indicates that there is problem with the DEF pump reverting valve or
4376-5 3862-5 Fluid Return Valve : Current Be-
the Pump Electronic Tank Unit (PETU) wiring harness.
low Normal
This code indicates that there is problem with the DEF pump reverting valve or
4376-6 3862-6 Fluid Return Valve : Current
the PETU wiring harness.
Above Normal
M0070030-01 401
Circuit Tests
Table 282
Required Tools
A T400242 Break-out Connector 1

B T400243 Break-out Connector 1

steps are listed.
402 M0070030-01
Circuit Tests
Table 283
1. Check for Opens in the PETU Wiring Harness for the Re- 10 Ohms Result: There were less than 10 Ohms of resistance on
verting Valve both of the reverting valve wires.
A. Turn the keyswitch to the OFF position for 2 minutes. The key- Proceed to Test Step 2.
switch must be OFF for 2 minutes to allow the DEF pump to purge,
reset the code, and reset the Diesel Exhaust Fluid Controller Result: There were more than 10 Ohms of resistance on
(DCU). either wire for the reverting valve.
B. Disconnect the PETU wiring harness from the DEF pump and Repair: There is an open in the harness. Repair the wir-
from the DCU. ing or replace the harness.
C. Connect Tooling (B) to the DCU connector. Connect Tooling (A) Verify that the problem is resolved. Proceed to Test Step
to the DEF pump connector. 4.
The connectors must be used to prevent damage to the DCU
and DEF pump connector.
D. Measure the resistance between terminal 11 (reverting valve +)

on the DEF pump connector and terminal 86 (reverting valve +) on
E. Measure the resistance between terminal 12 (reverting valve -)

on the DEF pump connector and terminal 65 (reverting valve -) on
2. Check for Short Circuits in the PETU Wiring Harness for 100k Ohms Result: There were more than 100 K Ohms of resistance
the Reverting Valve between the connector terminal and ground on both of
the reverting valve wires.
B. Disconnect the PETU wiring harness from the DEF pump.
Result: There were less than 100 K Ohms of resistance
C. Disconnect the 86-pin connector from the DCU. between the connector terminal and ground on either one
of the reverting valve wires.
D. Connect Tooling (A) to the DEF pump connector.
The connector must be used to prevent damage to the DEF Repair: There is a short circuit in the harness. Repair the
pump connector. wiring or replace the harness.
E. Measure the resistance between terminal 11 (reverting valve +) Verify that the problem is resolved. Proceed to Test Step
on the DEF pump connector and a known good chassis ground. 4.
F. Measure the resistance between terminal 12 (reverting valve -)

on the DEF pump connector and a known good chassis ground.
(continued)
M0070030-01 403
Circuit Tests
(Table 283, contd)

3. Check for Short Circuits in the PETU Wiring Harness for
the Reverting Valve 100k Ohms Result: There were more than 100 K Ohms of resistance
on both of the reverting valve wires.
Repair: A failed DEF pump has been detected. Replace
B. Disconnect the PETU wiring harness from the DEF pump. the DEF pump.
C. Disconnect the 86-pin connector from the DCU. Proceed to Test Step 4.
D. Connect Tooling (B) to the DCU connector. Result: There were less than 100 K Ohms of resistance
Tooling (B) must be used to prevent damage to the DCU on both of the reverting valve wires.
connector.
Repair: There is a short circuit in the harness. Repair the
E. Measure the resistance between terminal 86 (reverting valve +) wiring or replace the harness.
Verify that the problem is resolved. Proceed to Test Step
F. Measure the resistance between terminal 65 (reverting valve -) 4.
4. Perform a DEF Dosing System Verification Test DEF Dosing

System Verifica- Result: The codes did not return.
A. Turn the keyswitch to the ON position. Do not start the engine. tion Test
B. Connect to the “Diesel Exhaust Fluid Controller #1 ECM” in the
i06683185
DEF Tank Sensor - Test

system if a problem is suspected with the sensors.
Use this procedure if any of the diagnostic codes in
Table 284 are active or easily repeated.
404 M0070030-01
Circuit Tests
Table 284
The ECM detects signal voltage

that is not in the acceptable
1761-3 3130-3 Fluid Tank Level : Voltage Above
range.
Normal
The code is logged.

1761-4 3130-4 Fluid Tank Level : Voltage Below
range.
Normal
The code is logged.

3031-3 3134-3 Fluid Tank Temperature : Voltage
range.
Above Normal
The code is logged.

3031-4 3134-4 Fluid Tank Temperature : Voltage
range.
Below Normal
The code is logged.
The 5 VDC signal for the Diesel Exhaust Fluid (DEF)

tank level sensor is routed to terminal 1 of the tank
header unit. The 5 VDC signal for the DEF tank
temperature sensor is routed to terminal 3 of the tank
header unit. The sensor return is shared and is
routed to terminal 2 of the tank header unit. The ECM
provides short circuit protection for the internal power
supply. A short circuit to the battery will not damage
the internal power supply.
Diagnostics on the Electronic Service Tool

M0070030-01 405
Circuit Tests
The tank header unit houses the DEF tank

temperature and the DEF tank level sensors. The
sensors are not serviceable individually.
steps are listed.
Table 285
1. Check for Diagnostic Codes Diagnostic Result: A -3 diagnostic code is active.

Code
the Diesel Exhaust Fluid Controller (DCU) . Refer to Troubleshoot-
ing, “Electronic Service Tools”, if necessary. Result: A -4 diagnostic code is active.
B. Turn the keyswitch to the ON position. Proceed to Test Step 3.
C. Look for -3 or -4 active or logged codes.
2. 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. Verify that the harness connector is free of debris, free of corro-
sion and securely connected. Repair: The wiring is OK. Replace the DEF tank header
assembly. Refer to the Disassembly and Assembly
B. Install a jumper wire between the appropriate signal and return manual.
wire at the sensor connector to create a short. Verify that the problem is resolved by cycling the key-
switch to the OFF position for 2 minutes. Turn to the
C. Turn the keyswitch to the ON position. keyswitch to the ON position and check for active
codes.
D. Monitor the diagnostic codes on the electronic service tool. Check
for an active -4 diagnostic code for the suspect sensor. Result: A -4 diagnostic code does not become active
for the tank header unit.
Verify that the problem is resolved by cycling the key-
keyswitch to the ON position and check for active
codes.
3. Create an Open at the Suspect Sensor Connector Create an Result: A -3 diagnostic code became active after dis-
Open connecting the sensor.
A. Disconnect the connector of the tank header unit.
Repair: The wiring is OK. Replace the DEF tank header
B. Turn the keyswitch to the ON position. assembly. Refer to the Disassembly and Assembly
manual.
C. Monitor the diagnostic codes on the electronic service tool. Check Verify that the problem is resolved by cycling the key-
for an active -3 diagnostic code for the suspect sensor. switch to the OFF position for 2 minutes. Turn to the
D. Turn the keyswitch to the OFF position. codes.
Result: A -3 diagnostic code does not become active

after disconnecting the sensor.

Verify that the problem is resolved by cycling the key-
codes.
406 M0070030-01
Circuit Tests
i06917958
Electrical Power Supply - Test

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
286 are active or easily repeated.
Table 286

168-3 168-3 Electrical System Voltage : Volt- The ECM detects voltage that is
age Above Normal above the acceptable value.
168-4 168-4 Electrical System Voltage : Volt- The ECM detects voltage that is
age Below Normal below the acceptable value.
3360-3 3820-3 Aftertreatment 1 Diesel Exhaust The ECM detects voltage that is
Fluid Controller : Voltage Above above the acceptable value.
Normal
3360-4 3820-4 Aftertreatment 1 Diesel Exhaust The ECM detects voltage that is
Fluid Controller : Voltage Below below the acceptable value.
Normal
5758-11 3621-11 Engine Exhaust NOx Level Sen- The ECM detects voltage that is
sor Power Supply: Other Failure outside the acceptable value.
Mode
5759-11 3619-11 Aftertreatment #1 Outlet#1 NOx The ECM detects voltage that is
Level Sensor Power Supply: Oth- outside the acceptable value.
er Failure Mode
The engine ECM requires the keyswitch to be in the

ON position to maintain communications with the
M0070030-01 407
Circuit Tests
408 M0070030-01
Circuit Tests
Note: The DEF quality sensor is only available on the

2017model or later.
steps are listed.
Table 287
1. Determine the Diagnostic Code Diagnostic Code Result: A -3 or -11 diagnostic code is active.
A. Establish communication between the electronic service Proceed to Test Step 2.

tool and the ECM . Refer to Troubleshooting, “Electronic
Service Tools”, if necessary. Result: A -4 diagnostic code is active.
B. Start the engine. Run the engine until the engine is at Proceed to Test Step 3
normal operating temperature.
C. Observe the “Active Diagnostic” screen on the electronic

service tool. Wait at least 30 seconds so that any codes
may become active.
2. Check the Charging Circuit Charging Circuit Result: The charging system is OK.
A. Check the charging circuit. Refer to Systems Operation, Proceed to Test Step 3.
Testing and Adjusting, “Charging System - Test”.
Result: The charging system is not OK.
Repair: There is a problem with the charging system. Make

the necessary repairs. Refer to Systems Operation, Testing
and Adjusting, “Charging System - Test”.
3. Load Test the Battery Load Test Result: The battery voltage is low or the battery did not pass
the load test.
A. Load-test the battery. Refer to Systems Operation and
Testing and Adjusting, “Battery - Test” Repair: Recharge or replace the faulty batteries. Verify that
the repair eliminates the problem.
Result: The batteries pass the load test. The measured volt-
age is between 11.5 VDC and 13.5 VDC for a 12 v system.
The measured voltage is between 23.0 VDC and 27.0 VDC
for a 24 V system.
Verify that the “System Operating Voltage Configuration” is

correctly configured in the Engine ECM configuration
parameters.
Check the wiring between the batteries and the ECM / NOx
sensor. Refer to the application-specific wiring schematic for
pin locations.
Check the connectors between the batteries and the ECM /
NOx sensor for moisture and/or corrosion.
Repair: Repair or replace the wiring and/or the connectors.
Verify that the repair eliminates the problem.
M0070030-01 409
Circuit Tests
i06683237
Ether Starting Aid - Test
Before you test the ether injection system,

remove the ether canister from the system.
Use this procedure to troubleshoot the ether system
or use this procedure if a diagnostic code in Table
288 is active or logged.
Table 288
J1939 Code PDL Code Code Descriptions Comments

Ether Injection Control Solenoid : Cur- The code is latched. The code is logged.
626-5 2417-5
rent Below Normal Ether injection is disabled.
Ether Injection Control Solenoid : Cur- The code is latched. The code is logged.
626-6 2417-6
rent Above Normal Ether injection is disabled.
The ether injection system will improve cold weather

starting of the engine. The engine Electronic Control
Module (ECM) controls the ether injection system.
The ether injection system is disabled if there is an
active engine shutdown.
Activation of the ether starting aid is based from a
map using the coolant temperature, intake manifold
temperature, and atmospheric pressure. Refer to
Illustration 144 .
410 M0070030-01
Circuit Tests
The following conditions must be met for the ether

injection system to be enabled:
• Ether injection is set to “Enabled” in the electronic

service tool.
• Engine coolant temperature is less than the “Start
Aid Selection Temperature - Coolant” . Refer to
Illustration 144 .
• Intake manifold temperature is less than the “Start
Aid Selection Temperature - IMAT.”
• Coolant temperature and intake manifold air
temperature are within 11° C of each other.
Ether starting aid group (typical example)
(1) Ether injection solenoid
M0070030-01 411
Circuit Tests

Terminal locations at the harness connector for the
ether solenoid
(1) Ether enable solenoid
(2) Return for ether injection solenoid

412 M0070030-01
Circuit Tests
Table 289
1. Inspect Electrical Connectors and Wiring Connectors and Result : The harness and wiring are OK.
Wiring
A. Remove the electrical power from the ECM. Proceed to Test Step 2.
B. Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Result : There is a problem in the connectors and/or wiring.
Inspect all the other connectors for the circuit. Refer to the di-
agnostic functional test Troubleshooting, “Electrical Connec- Repair : Repair the connectors or wiring and/or replace the
tors - Inspect”. connectors or wiring. Ensure that all the seals are properly
in place and ensure that the connectors are coupled.
C. Perform a 45 N (10 lb) pull test on each of the wires in the
ECM connector that are associated with the circuit. Proceed to Test Step 4.
D. Check the ECM connector (allen head screw) for the prop-
er torque. Refer to the diagnostic functional test Troubleshoot-
ing, “Electrical Connectors - Inspect”.
E. Check the harness and the wiring for abrasion and for
pinch points.
2. Check the Wiring Between the ECM and the Ether 10 VDC Result : The voltage measured 0 VDC.
Control
Repair : There is a problem in an electrical component be-
The ether canister must be removed prior to performing tween the ECM and the harness connector for the ether
this procedure. control. The problem may be inside an electrical connector.
Make the necessary repairs.
A. Verify that the keyswitch is in the OFF position.
B. Remove the ether canister.
Result : The voltage measured greater than 10 VDC.
C. Disconnect the engine harness connector for the ether
control. Repair : The electrical components between the ECM and
the harness connector for the ether control are OK.
D. Connect a digital voltmeter across the two terminals on the
engine 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 when the key-

switch is turned ON.
3. Measure the Resistance of the Coil Inside the Ether 20 Ω Result : The measured resistance was approximately 20 Ω.
Control
A. Verify that the ether control is not connected to the engine
harness. Result : The measured resistance was not approximately
20 Ω.
B. Measure the resistance of the coil inside the ether control.
Repair : Replace the ether control. Proceed to Test Step 4.
M0070030-01 413
Circuit Tests

Retracted plunger

Extended plunger
Table 290
4. Verify the Repair Plunger Movement Result : The plunger moved up when the override was
active.
A. Activate the Ether Injection Override.
Repair : Install the ether bottle and return the unit to
B. Verify that the plunger moved up when the override was service.
active.
i06268988 Table 291

Required Tooling
Exhaust Balance Valve - Test
Tooling Quantity Description
A 1 Pressure regulator
Note: This test checks the Exhaust Balance Valve for B 1 Pressure gauge (
proper operation. Component locations outlined in 207 kPa (30 psi))
this procedure may not represent all applications.
Refer to the system operations manual of the C 2 Gate valve
machine or engine you are working on for correct
component locations.
(continued)
414 M0070030-01
Circuit Tests
(Table 291, contd)

D 1 061-7921 7/16"-20
JIC to 1/4" NPTF
E 1 006-6586 1/4"-18
NPTF to hose barb

Typical example of the required tooling
(A) Pressure regulator
(B) Pressure gauge
(C) Gate valves

(1) Connection points to check
Table 292
1. Inspect the Air Lines from the Exhaust Balance Valve Sole- Damaged air Result: A line is damaged.
noid to the Exhaust Balance Valve Actuator line
Repair: Repair the line or replace the line. Return the unit to
Inspection of the air lines is difficult in some applications. Test Step service.
5 will provide further testing procedures.
Result: A line is not damaged.
A. Inspect the air lines from the outlet of the exhaust balance valve
solenoid to the inlet of the exhaust balance valve actuator. Inspect Proceed to Test Step 2.
the lines for any signs of leakage.
M0070030-01 415
Circuit Tests
(2) Linkage to the exhaust balance valve (3) Connection point from the exhaust -up at this linkage is normal
balance valve to the linkage, soot build
Table 293
2. Inspect the Linkage to the Exhaust Balance Valve Damaged or Result: The linkage is damaged.
broken
A. Inspect the linkage to the exhaust balance valve from the canis- linkage Repair: Replace the turbocharger. Return the unit to
ter to the housing. Also, inspect the connection point from the link- service.
age to the valve. Inspect the linkage for the following issues:
1. Bending Result: The linkage is not damaged.
2. Breakage
416 M0070030-01
Circuit Tests
(4) Pressure regulator (7) Hose from the mixer to the exhaust (9) Exhaust balance valve
(5) Gate valve # 1 balance valve solenoid (10) Gate valve # 2
(6) Pressure gauge (8) Exhaust balance valve solenoid
(7) Hose
Only disconnect the hose from the mixer, do not

disconnect the hose from the balance valve solenoid.
M0070030-01 417
Circuit Tests

(5) Gate valve #1
(10) Gate valve #2

(11) Fitting for the line to the exhaust balance valve
418 M0070030-01
Circuit Tests
Table 294
3. Test the Exhaust Balance Valve Solenoid to Make Sure that Valve stuck Result: Air leaked out of the line from the exhaust balance
the Valve Is Not Stuck in the CLOSED Position closed valve solenoid after the fitting was loosened.
A. Disconnect hose (7) from the mixer. Refer to Illustration 154 . The solenoid is not stuck closed. Proceed to Test Step 4.
B. Connect Tooling (A), (B), (C), and necessary adapters between Result: Air did not leak out of the line from the exhaust bal-
hose (7) and the mixer. The other end of hose (7) must stay con- ance valve solenoid after the fitting was loosened.
nected to the inlet of the balance valve solenoid.
The exhaust balance valve solenoid is not operating prop-
C. Turn the keyswitch to the OFF position. erly. Replace the exhaust balance valve solenoid. Return the
unit to service.
Only apply 138 kPa (20 psi) air pressure to the exhaust bal-
ance valve.
D. With gate valve (5) in the open position, regulate the supply air
pressure to 138 kPa (20 psi). Make sure gate valve (10) is closed.
Once the pressure is stable, close gate valve (5).
E. Loosen fitting (11) for the line from the exhaust balance valve
solenoid to the exhaust balance valve.
4. Test the Exhaust Balance Valve Solenoid to Make Sure that Valve stuck Result: Air leaked out of the line from the exhaust balance
the Valve Is Not Stuck in the OPEN Position open valve solenoid after the line was loosened.
The exhaust balance valve solenoid is not operating
A. Relieve any residual pressure in the system by using gate valve properly.
(10) . Once the pressure is relieved, close the valve.
Repair: Replace the exhaust balance valve solenoid. Return
Only apply 138 kPa (20 psi) air pressure to the exhaust bal- the unit to service.
ance valve.
Result: Air did not leak out of the line from the exhaust bal-
B. With the gate valve (5) in the open position, regulate the supply ance valve solenoid after the line was loosened.
air pressure to 138 kPa (20 psi). Make sure gate valve (10) is
closed. Once the pressure is stable, close gate valve (5). The solenoid is operating properly, Proceed to Test Step 5.
D. In the electronic service tool, navigate to the “Engine Exhaust

Manifold Bank #1 Flow Balance Valve Solenoid Override” “Over-
ride Parameters” menu under the diagnostic tab. Override the ex-
haust balance valve to ON.
E. Loosen the line to the balance valve from the exhaust balance
valve solenoid.
(continued)
M0070030-01 419
Circuit Tests
(Table 294, contd)

5. Pressure Test the System for Leaks System leaks Result: The pressure on the gauge maintains approximately
138 kPa (20 psi).
A. Relieve any residual pressure in the system by using gate valve
(10). Once the pressure is relieved, close the valve. There are no leaks in the system. Proceed to Test Step 6.
Only apply 138 kPa (20 psi) air pressure to the exhaust bal- Result: The pressure on the gauge does not maintain
ance valve. 138 kPa (20 psi).
There is a leak in the system.
B. With the gate valve (5) in the open position, regulate the supply
air pressure to 138 kPa (20 psi). Make sure gate valve (10) is Repair: Check all lines and connections and repair the leak.
closed. Once the pressure is stable, close gate valve (5). Return the unit to service.
C. Turn the keyswitch ON in order to activate the exhaust balance

valve solenoid.
Air should now flow between gate valve (5) and the exhaust bal-
ance valve.
6. Check the Spring for the Exhaust Balance Valve Broken Result: The linkage will move by hand.
spring
A. Remove all air pressure from the exhaust balance valve Repair: Replace the exhaust balance valve actuator. Return
actuator. the unit to service.
B. Try to move the linkage rod for the exhaust balance valve by Result: The linkage would not move by hand.
hand.
420 M0070030-01
Circuit Tests
(12) Cover for the exhaust balance valve

chamber
Table 295
7. Inspect the Exhaust Balance Valve Damaged or Result: The exhaust balance valve is broken.
broken valve
A. Relieve all pressure from the exhaust balance valve system. Repair: Replace the turbocharger. Return the unit to
service.
B. Remove the cover from the exhaust balance valve chamber.
C. Ensure that the exhaust balance valve is not broken.

steps are listed.
i06683284
Injector Solenoid - Test

trouble codes:
M0070030-01 421
Circuit Tests
Table 296

Cylinder #1 Injector : Current
651-5 1-5
Below Normal
651-6 1-6
Above Normal
652-5 2-5
Below Normal
652-6 2-6
Above Normal
653-5 3-5
Below Normal
653-6 3-6
Above Normal
These codes relate to the electrical circuit that in-
Cylinder #4 Injector : Current cludes injector terminals 1 and 3.
654-5 4-5
Below Normal
654-6 4-6
Above Normal
655-5 5-5
Below Normal
655-6 5-6
Above Normal
656-5 6-5
Below Normal

656-6 6-6
Above Normal
Cylinder #1 Injector Actuator #2

3659-5 2602-6
: Current Above Normal

3659-6 2602-5
: Current Below Normal
3660-5 2604-6
3660-6 2604-5
3661-5 2606-6 These codes relate to the electrical circuit that in-
cludes injector terminals 2 and 4.
3661-6 2606-5
3662-5 2608-6
3662-6 2608-5
3663-5 2610-6
3663-6 2610-5
(continued)
422 M0070030-01
Circuit Tests
(Table 296, contd)


3664-5 2612-6
3664-6 2612-5
Background Information
These engines have Electronic Unit Injectors (EUI)
that are electronically controlled. Each injector
contains two solenoids. The Electronic Control
Module (ECM) sends 105 v pulses to each injector
solenoid. The pulses are sent at the proper time and
at the correct duration for a given engine load and
speed.
The ECM monitors the current flow through the circuit
for each solenoid. If low current flow is detected, a
diagnostic code is activated. The ECM continues to
try to fire the injector.
If high current flow is detected, a diagnostic code is
activated. The ECM will disable the solenoid circuit to
prevent damage from the high current flow. However,
the ECM will periodically try to fire the injector. If the
short circuit remains, this sequence of events will be
repeated until the problem is corrected.
Typically, problems with an injector solenoid occur
when the engine is warmed up and/or when the
engine is under vibration (heavy loads). Perform this
procedure when the engine is at normal operating
temperature. Pay careful attention to the condition of
the wiring and the connectors as you perform this
procedure. The wiring and/or the connectors may
have problems that only occur during vibration.
Diagnostic Tests on the Electronic Service Tool
The electronic service tool includes the following test
that aids in troubleshooting injector solenoids:
Injector Solenoid Test – The Injector Solenoid Test
identifies an open circuit or a short circuit in the
circuits for the injector solenoids. The test is
performed when the engine is not running. The
“Injector Solenoid Test” briefly activates each
solenoid. A good solenoid will create an audible click
when the solenoid is activated. The electronic service
tool indicates the status of the solenoid as “OK” ,
“Open” , or “Short” .
Note: Refer to the following schematic. Two injector

solenoids share a common supply wire. For this
reason, an open circuit or a short circuit in a supply
wire could cause diagnostic codes for two cylinders.
M0070030-01 423
Circuit Tests
424 M0070030-01
Circuit Tests
Table 297
1. Check for Logged Codes or Active Codes Leakage Result: There are codes other than an injector code active
or logged.
and the ECM . Refer to Troubleshooting, “Electronic Service Tools”, Repair: Refer to the appropriate troubleshooting procedure.
if necessary.
Result: A -5 code or a -6 code is logged or active.
2. Inspect the Wiring Harness Between the ECM and the Valve Damaged Result: The connectors and the wiring appear to be OK.
Cover Base wiring or The harness between the ECM and the connector does not
connectors have an open circuit.
B. Thoroughly inspect the connectors. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details. Result: There is a problem with the connectors and/or
wiring.
C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM
connector. Perform a pull test on each of the wires that are associ- Repair: Repair the connectors or wiring and/or replace the
ated with injector solenoids. connectors or wiring. Ensure that all the seals are properly
in place and ensure that the connectors are coupled. Per-
D. Check the allen head screw on the ECM connector for the prop- form an injector solenoid test to verify that the problem has
er torque. Refer to Troubleshooting, “Electrical Connectors - In- been resolved.
spect” for the correct torque values.
E. Check the harness and wiring for abrasions and for pinch points
from the valve cover base to the ECM.
(continued)
M0070030-01 425
Circuit Tests
(Table 297, contd)

Short circuit
3. Check the Harness between the ECM and the Valve Cover is detected Result: The electronic service tool displays a -6 code for
Base for an Open Circuit each circuit that was jumpered.
The harness between the ECM and the connector does not
A. Turn the keyswitch to the OFF position. A strong electrical shock have an open circuit.
hazard is present if the keyswitch is not turned off.
B. Remove electrical power from the engine ECM.
Result: The electronic service tool does not display a -6
C. Disconnect the connectors of the injector harness at the valve code for the cylinder with the jumper wire.
cover base.
Repair: Repair the harness or replace the harness between
D. Fabricate a jumper wire long enough to create a short circuit on the ECM and the valve cover base. Perform an injector sole-
the different terminal locations at the connector of the injector har- noid test to verify that the problem is resolved.
ness. Crimp connector pins on both ends of the jumper wire.
E. Insert one end of the jumper wire into the connector socket for
the suspect injectors supply wire. Insert the other end of the jumper
wire into the connector socket for the suspect injectors return wire.
The jumper wire will bypass the injector solenoid.
F. .Restore electrical power to the engine ECM.
G.Turn the keyswitch to the ON position.
H. Perform the “Injector Solenoid Test” in tool.
I. Repeat this test for each suspect circuit. Stop the “Injector Sole-
noid Test” before handling the jumper wire. Restore the wiring to
the original configuration.
Open circuit
4. Check the Harness between the ECM and the Valve Cover detected Result: All cylinders indicate a -5 code on the electronic
Base for a Short Circuit service tool.
The harness between the ECM and the connector does not
A. Turn the keyswitch to the OFF position. A strong electrical shock have a short circuit.
Result: One or more cylinders indicate a -6 code on the
C. Disconnect the connectors of the injector harness at the valve electronic service tool. Note the cylinders that indicate
cover base. “Short” . The problem is in the wiring to the ECM or the ECM
is not operating properly.
D. Restore electrical power to the engine ECM.
Repair: Repair the wiring or replace the wiring to the ECM.
E. Turn the keyswitch to the ON position. Perform an injector solenoid test to verify that the problem is
resolved.
F. Perform the Injector Solenoid Test at least two times.
(continued)
426 M0070030-01
Circuit Tests
(Table 297, contd)

5. Inspect the Wiring Harness Between the Valve Cover Base Damaged Result: The connectors and the wiring appear to be OK.
and the Injectors wiring or
connectors Proceed to Test Step 6.
A. Turn the keyswitch to the OFF position. A strong electrical shock
hazard is present if the keyswitch is not turned off. Result: There is a problem with the connectors and/or
wiring.
Repair: Repair the connectors or wiring and/or replace the
C. Thoroughly inspect the connectors. Refer to Troubleshooting, connectors or wiring. Ensure that all the seals are properly
“Electrical Connectors - Inspect” for details. in place and ensure that the connectors are coupled.
Perform an injector solenoid test to verify that the problem is
D. Perform a 45 N (10 lb) pull test on each of the wires that are as- resolved.
sociated with injector solenoids.
E. Check the harness and wiring for abrasions and for pinch points
from the valve cover base to the injectors.
Open circuit
6. Check the Injector Harness under the Valve Cover for a detected Result: The electronic service tool displays “Open” for the
Short Circuit solenoid that is not connected.
A. Turn the keyswitch to the OFF position. A strong electrical shock Proceed to Test Step 7.
Result: The electronic service tool displays “Short” for the
B. Remove electrical power from the engine ECM. solenoid that is not connected.
There is a problem with the injector harness under the valve
C. Remove the valve cover to gain access to the suspect injector. cover.
D. Disconnect the harness connector from the suspect injector. Repair: Repair the wiring and/or the connector, when possi-
ble. Replace parts, if necessary.
E. Inspect the seal around each wire. Verify that the seal is sealing Perform an injector solenoid test to verify that the problem is
correctly. resolved.
F. Pull on each wire to verify that the wire and the terminal are cor-
rectly installed.
G. Restore power to the ECM.
H. Turn the keyswitch ON.
I. Activate the “Injector Solenoid Test” . Allow the Injector Solenoid

Test to continue until each solenoid is activated at least two times.
7. Check the Injector Harness under the Valve Cover for an Short circuit Result: The electronic service tool displays “Short” for the
Open Circuit detected connector that has the jumper wire. The wiring is OK.
A. Turn the keyswitch to the OFF position. A strong electrical shock Replace the suspect injector. Perform an “Injector Solenoid
hazard is present if the keyswitch is not turned off. Test” using the electronic service tool to verify that the prob-
lem is resolved.
Result: The electronic service tool displays “Open” for the
C. Determine the appropriate terminals for the solenoid with the connector that has the jumper wire.
code. Connect a jumper wire between the terminal for the supply
and the terminal for the return. The jumper wire will replace the in- The wiring has an open.
jector solenoid with a short circuit. Repair: Repair the harness or replace the harness under
the valve cover. Perform an injector solenoid test to verify
D. Turn the keyswitch ON. that the problem is resolved.
E. Activate the “Injector Solenoid Test” . Allow the Injector Solenoid

Test to continue until each solenoid is activated at least two times.
M0070030-01 427
Circuit Tests
i06687660
NOx Reduction System (NRS) -

Test
The exhaust gas that flows from the exhaust manifold

is mixed with fresh air. The NRS meters the mixture
of air and exhaust. The NRS also cools the mixture.
This mixture will reduce the NOx emissions of the
engine.
The following NRS consists of the following
components:
• NRS cooler
• NRS venturi
• NRS absolute pressure sensor
• NRS differential pressure sensor

• NRS temperature sensor
• NRS valve
The following diagnostic trouble codes aid in
detection of pressure and air flow issues within the
NRS.
Table 298
Code Description
The ECM detects an abnormally

411-15 E1094 (1) High EGR Differential Pressure high reading from the NRS differen-
tial pressure sensor.
The ECM detects an abnormally low

411-17 E1093 (1) Low EGR Differential Pressure reading from the NRS differential
pressure sensor.
The ECM detects a higher than desired
2659-15 E1096 (1) High EGR Mass Flow Rate
flow rate through the NRS
The Electronic Control Module (ECM)

2659-17 E1095 (1) Low EGR Mass Flow Rate detects a lower than desired flow rate
through the NRS
Note: EGR is an industry standard term used to Table 299

describe the recirculation of exhaust gas through the Associated Diagnostic Trouble Codes
engine as a means to reduce “NOx” emissions.
Perkins has elected to refer to this system as the J1939 Code PDL Code
“NOx Reduction System” (NRS). Diagnostic codes 3609-17 E1154 (1)
are regulated by SAE, therefore, the diagnostic
codes still reflect the EGR nomenclature.
(continued)
428 M0070030-01
Circuit Tests
(Table 299, contd)

3609-18 E1154 (2)
412-15 E1092 (1)
412-16 E1092 (2)

steps are listed.
Table 300
1. Check for Diagnostic Trouble Codes Associated Result: There are associated codes.
Codes
A. Establish communication between the electronic service tool Repair: Refer to Troubleshooting, “Event Codes” to trouble-
and the ECM . Refer to Troubleshooting, “Electronic Service shoot the associated diagnostic code.
Result: There are no associated codes. If the original diag-
B. Troubleshoot any active or logged diagnostic trouble codes be- nostic trouble code was a E1095, E1096, 2659-15 and/or a
fore troubleshooting the event codes outlined in this procedure. 2659-17.
Determine if an associated code is active or logged. Table 299 lists
associated diagnostic codes. Proceed to Test Step 2.

nostic trouble code was a E1093, E1094, 411-17 and/or 411-
15.

nostic trouble code was a E1095 or 2659-17.
M0070030-01 429
Circuit Tests

Inspection points for the left side of the engine
(1) NRS inlet valve (2) NRS temperature sensor (3) NRS outlet valve
430 M0070030-01
Circuit Tests

Inspection points for the right side of the engine
(4) NRS cooler outlet (5) NRS cooler inlet (6) NRS bellows joint
M0070030-01 431
Circuit Tests
Table 301
2. Inspect the NRS for Leakage Leakage Result: Leaks were found in the system.
A. Inspect the following components of the NRS for leakage: Repair: Repair the leaks.
1. Exhaust manifold Reset all active codes and clear all logged codes. Use the
electronic service tool to perform an “EGR System Test” to
2. Connections for NRS cooler inlet and NRS cooler outlet verify that the problem is resolved.
3. NRS venturi inlet and outlet connections Result: Leaks were not found in the system.
4. Port locations for NRS differential pressure sensor and NRS ab- Proceed to Test Step 3.
solute pressure sensor
5. Connections for NRS inlet valve and NRS outlet valve
Common signs of a leak in the NRS are loose connections, dam-

aged lines, or components and exhaust soot buildup around the
area that is leaking.
3. Use the Electronic Service Tool to Perform an “ EGR System Test Failed Result: The “EGR System Test” fails due to “Delivered Fuel
Test”” Volume Not Responding” .
A. Start the engine. When the NRS gas flow is being commanded to change, no
change in fuel delivery was measured. Increasing or de-
B. Use the electronic service tool to perform an “EGR System Test” creasing the NRS gas flow will affect the amount of fuel
. needed to maintain the desired engine speed.
Result: The “EGR System Test” fails due to “EGR Delta

Pressure Not Responding” .
The fault indicates that when the NRS valve moves from
OPEN to CLOSED, no change in NRS delta pressure is
measured.
Result: The “EGR System Test” fails due to “EGR Absolute

Pressure Not Responding” .
The fault indicates that when the NRS valve moves from
OPEN to CLOSED, no change in the NRS absolute pressure
is measured.
Result: The “EGR System Test” fails due to “EGR Mass

Flow Rate Incorrect” .
The fault indicates when the NRS valve moves from OPEN
to CLOSED, the desired NRS mass flow is different from the
actual mass flow rate.
432 M0070030-01
Circuit Tests

NRS valve
(7) NRS actuator assembly (8) NRS valve body

NRS valve
(9) Point of rotation
M0070030-01 433
Circuit Tests
Table 302
4. Inspect the NRS Valve Valve Ro- Result: NRS valve does not rotate at all, or the valve is diffi-
tates Freely cult to rotate.
A. Remove actuator assembly from NRS valve body.
Repair: Replace the NRS valve body and install the actuator
B. Use a straight screwdriver to rotate the valve inside the NRS assembly that was previously removed.
valve body. The valve should freely rotate from the open to close
positions for 90 degrees of rotation. Reset all active codes and clear all logged codes by cycling
the keyswitch to the OFF position. Use the electronic service
tool to perform an “EGR System Test” to verify that the prob-
lem is resolved.
Result: NRS valve does rotate freely from open to close.
Repair: Install new actuator assembly.

Reset all active codes and clear all logged codes by cycling
lem is resolved.

Typical mounting locations for the NRS sensors
(10) NRS differential pressure sensor (12) Mounting point for NRS differential
(11) NRS absolute pressure sensor pressure sensor
434 M0070030-01
Circuit Tests
Table 303
5. Inspect the Mounting Location for the NRS Differential Soot Build- Result: Soot build-up is evident in the NRS differential pres-
Pressure Sensor Up sure sensor passages.
A. Refer to Troubleshooting, “Electrical Connectors - Inspect” Repair: Remove the NRS venturi. Use hot soapy water and
when checking sensors. a bore brush to clean out the passages for the NRS venturi
differential pressure.
B. Remove the NRS differential pressure sensor.
C. Inspect the mounting location for signs of accumulations of the keyswitch to the OFF position. Use the electronic service
soot. The accumulation may indicate further accumulations of soot tool to perform an “EGR System Test” to verify that the prob-
downstream in the pressure passages. lem is resolved.
Result: Little or no soot build-up evident.
Repair: Replace the NRS differential pressure sensor.
lem is resolved.

Typical mounting locations for the NRS sensors
(13) NRS differential pressure sensor (15) Mounting point for NRS absolute
(14) NRS absolute pressure sensor pressure sensor
M0070030-01 435
Circuit Tests
Table 304
6. Inspect the NRS Absolute Pressure Sensor and the Mount- Soot Build- Result: Soot build-up is evident in the absolute pressure
ing Location Up sensor passage.
A. Refer to Troubleshooting, “Electrical Connectors - Inspect” Repair: Remove the NRS venturi. Use hot soapy water and
when checking sensors. a bore brush to clean the passages. Install the NRS venturi.
B. Remove the NRS absolute pressure sensor. Reset all active codes and clear all logged codes. Use the
electronic service tool to perform an “EGR System Test” to
C. Visually inspect all the mounting locations for signs of excessive verify that the problem is resolved.
soot. The excessive soot may indicate further buildup downstream
in the pressure passages. Result: Little or no soot build-up evident.
Repair: Replace the NRS absolute pressure sensor.
lem is resolved.
i06920117
NOx Sensor - Test
The ECM is monitoring the NOx level being reported

by the sensor. If the NOx value is not steady when
the engine speed/fueling is steady, the codes listed
below will log. If the NOx value is steady when the
engine speed/load is changing, the codes listed
below will log.
Table 305 lists the diagnostic codes for the NOx
sensors.
Table 305

PDL Code Comments
Code
Aftertreatment #1 Intake NOx : The aftertreatment intake NOx level is not responding as expected.
3216-7 E1431 (2)
Not Responding Properly The code is logged.
Aftertreatment #1 Outlet NOx : The aftertreatment outlet NOx level is not responding as expected.
3226-7 E1432 (2)
Not Responding Properly The code is logged.
Table 306
Required Tools
Qty Part Number Part Description

1 T400236 Kit - Test
1 T40-0195 Refractometer

steps are listed.
436 M0070030-01
Circuit Tests
Table 307
1. Check the Diesel Exhaust Fluid (DEF) quality. DEF Quality 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.
Result : The DEF is not contaminated and the concentra-

tion is within the acceptable range.
Repair : Contact the Dealer Solution Network (DSN) for

2. Perform a DEF Dosing System Accuracy Test. DEF Dosing Result : The quantity collected is within specifications.
System Accu-
A. Perform a “DEF Dosing System Accuracy Test” using the elec- racy Test Repair : Install the DEF injector.
tronic service tool. Refer to Systems Operation, Testing and Ad-
justing, “Aftertreatment SCR System Dosing Test” for the correct Proceed to Test Step 4.
procedure.
Result : The quantity collected is below specification.
Result : The quantity collected is above specification. A

failed DEF injector has been detected.
Repair : Replace the failed DEF injector.
3. Check the DEF Pressure Line. Restrictions, Result : There are restrictions or leaks in the lines.
Obstructions, or
A. Turn the keyswitch to the OFF position. Allow 2 minutes to Leaks Repair : Remove the restrictions or replace the pressure
elapse before proceeding. line.
B. Visually inspect the lines for leaks or damage. Proceed to Test Step 4.
C. Remove the DEF pressure line between the DEF pump and the Result : There are no restrictions or leaks in the lines.
DEF injector. Refer to the Disassembly and Assembly manual for
the correct procedure. Repair : Proceed to Troubleshooting, “DEF Pressure is
Low”.
D. Inspect the DEF pressure line for obstructions. Flush the line
with water or low-pressure air, if necessary. Possible obstructions
are ice, DEF deposits, or debris.
(continued)
M0070030-01 437
Circuit Tests
(Table 307, contd)

4. Perform an “ Aftertreatment System Functional Test”” Successful Test Result : The test completed successfully.
A. Establish communication between the electronic service tool Return the unit to service.
and the engine Electronic Control Module (ECM) . Refer to Trou-
bleshooting, “Electronic Service Tools”, if necessary. Result : The test did not complete successfully.
B. Perform an “Aftertreatment System Functional Test” using the Proceed to Test Step 5.
5. Check for an Engine Misfire Misfire Result : A misfire was detected.
A. Establish communication between the electronic service tool Repair : Replace or repair the failed component or
and the engine Electronic Control Module (ECM) . components.
B. Perform a “Cylinder Cutout Test” using the electronic service Proceed to Test Step 7.
tool.
Result : A misfire was not detected.
6. Check the Exhaust System for Leaks Exhaust Leaks Result: There were not any exhaust leaks found.
A. Check the entire exhaust system for leaks. Repair : For a 3216-7 (E1431 (2)) code, replace the in-
take NOx sensor.
Repair : For a 3226-7 (E1432 (2)) code, replace the outlet

NOx sensor.
Result : There were exhaust leaks found.
Repair : Repair the exhaust leaks.
7. Perform the “ Aftertreatment System Functional Test”” in the Successful Test Result: The test completed successfully.
and the engine Electronic Control Module (ECM) . Refer to Trou-
B. Perform the “Aftertreatment System Functional Test” using the

i06688778
Retarder - Test
Use this procedure for the following diagnostic

trouble codes:
438 M0070030-01
Circuit Tests
Table 308
Diagnostic Codes

1072-5 2533-5 Compression Brake Low/High The code is logged.

Solenoid #1 : Current Below
Normal
1072-6 2533-6 Compression Brake Low/High The code is logged.
Solenoid #1 : Current Above
Normal
1073-5 2535-5 Compression Brake Medium/High The code is logged.
Solenoid #1 : Current Below
Normal
1073-6 2535-6 Compression Brake Medium/High The code is logged.
Solenoid #1 : Current Above
Normal
The compression brake uses the engine to provide

auxiliary braking for the machine. The compression
brake reduces wear of the wheel brake components,
brake oil temperature, and the chance for engine
overspeed. The compression brake also aids in the
controllability of the machine.
If the retarder is installed on the engine, the
configuration parameter for the engine retarder must
be set to “Enabled” for this function to operate. The
engine ECM will activate the appropriate
compression brake solenoids to meet the requested
level of braking.
“ Compression Brake Solenoid Override””
The Compression Brake Low/High Override and
Compression Brake Med/High Override are
diagnostic overrides that are available on the
electronic service tool. Use the overrides to help with
troubleshooting problems in the circuit for the
compression brake. The ECM will only detect shorts
in the circuit for the compression brake when the
overrides are active. The overrides must be activated Illustration 165 g01199118
and then deactivated before the ECM will detect an
open circuit. The ECM will only detect opens in the Location of the compression brake solenoid (typical
circuit for the compression brake when the overrides example)
are not active.
Note: The engine speed must be zero before the
overrides will function.
M0070030-01 439
Circuit Tests

steps are listed.
Table 309
1. Check for Active Diagnostic Codes and/or Logged Diag- Diagnostic Result: A 2533-5 diagnostic code or a 2535-5 diagnostic
nostic Codes Trouble code is active. If both diagnostic codes are active, the prob-
Codes lem is most likely in the shared return wire. Inspect the wire
A. Connect the electronic service tool to the service tool and/or connectors for an open circuit.
connector.
Result: A 1072-5 diagnostic code or a 1073-5 diagnostic
C. Access the diagnostic overrides under the “Diagnostics” menu. code is active. If both diagnostic codes are active, the prob-
lem is most likely in the shared return wire. Inspect the wire
D. Start the “Compression Brake Low/High Override” on the elec- and/or connectors for an open circuit.
E. Once the electronic service tool displays the status of the com-
pression brake solenoid, stop the “Compression Brake Low/High Result: A 2533-6, diagnostic code or a 2535-6 diagnostic
Override” . code is active.
F. Monitor the active diagnostic code screen on the electronic Proceed to Test Step 4.
Result: A 1072-6 diagnostic code or a 1073-6 diagnostic
G. Start the “Compression Brake Med/High Override” on the elec- code is active.
H. Once the electronic service tool displays the status of the com-
pression brake solenoid, stop the “Compression Brake Med/High
Override” .
I. Monitor the active diagnostic code screen on the electronic serv-

ice tool. Check and record any active diagnostic codes.
440 M0070030-01
Circuit Tests
Table 310
2. Create a Short Between the Wires of the Suspect Compres- Short Circuit Result: A 2533-6, 1072-6, 1073-6, or a 2535-6 diagnostic
sion Brake Solenoid at the Valve Cover Connector Detected code is active. The harness wiring between the valve cover
connector and the ECM is OK.
To troubleshoot a 2533-5 or 1072-5 diagnostic code, use the
“ Compression Brake Low/High Override”” on the electronic Proceed to Test Step 3.
service tool. To troubleshoot a2535-5 or 1073-5 diagnostic
code, use the “ Compression Brake Med/High Override”” on the Result: A 2533-5, 1072-5, 1073-5, or a 2535-5 diagnostic
electronic service tool. code is active. The ECM did not detect the short at the valve
cover connector.
Repair: Repair the harness or replace the harness. Verify
B. Disconnect the harness at the valve cover connector. that the problem is resolved.
C. Fabricate a jumper wire to create a short between the supply

wire for the suspect compression brake solenoid and engine
ground.
E. Access the diagnostic overrides under the “Diagnostics” menu.
F. Start the override for the compression brake.
G. Once the electronic service tool displays the status of the com-
pression brake solenoid, stop the override.
H. Monitor the active diagnostic code screen on the electronic

I. Turn the keyswitch to the OFF position. Remove the wire short.
A -5 open circuit diagnostic code will be active for the other com-
pression brake solenoid. Ignore the diagnostic codes for the other
compression brake solenoid. Ignore any diagnostic codes for the
injector solenoids.
M0070030-01 441
Circuit Tests
Table 311
Short Circuit
3. Create a Short Circuit at the Compression Brake Solenoid Detected Result: A 2533-6, 2535-6, 1072-6, or a 1073-6 diagnostic
code is active. The harness wiring between the connector
Two solenoids are activated to create a medium braking ac- for the compression brake solenoid and the ECM is OK.
tion. The open could be in either solenoid or in the harness.
To isolate the problem for a medium braking action, run this Repair: Replace the suspect compression brake solenoid.
test step for each of the solenoids. The short must be created Verify that the problem is resolved.
separately at each solenoid.
To troubleshoot a 2533-5 or 1072-5 diagnostic code, use the Result: A 2533-6, 2535-6, 1072-6, or a 1073-6 diagnostic
“ Compression Brake Low/High Override”” on the electronic code is active. The ECM did not detect the short at the con-
service tool. To troubleshoot a 2535-5 or a 1073-5 diagnostic nector for the compression brake. There is an open between
code, use the “ Compression Brake Med/High Override”” on the the valve cover connector and the connector for the com-
electronic service tool. pression brake solenoid.
A. Turn the keyswitch to the OFF position. Repair: Repair the harness or replace the harness between
the connector for the compression brake solenoid and the
B. Remove the valve cover. valve cover connector.
C. Reconnect the valve cover connector.
D. Disconnect the connector on the suspect compression brake

solenoid.
E. Inspect the terminals on the connector for the compression

brake solenoid for damage.
F. Fabricate a jumper wire. Short the two wires for the suspect sol-
enoid on the solenoid connector. Crimp a pin to each end of the
jumper wire.
G. Make sure that the solenoid connector securely holds the jump-
er wire.
Worn terminals and/or damaged terminals on the solenoid
connector could cause an intermittent “ Open”” .
H. Turn the keyswitch to the ON position.
I. Access the diagnostic override under the “Diagnostics” menu.
J. Start the override for the compression brake.
K. Once the electronic service tool displays the status of the com-
L. Monitor the active diagnostic code screen on the electronic

M. Turn the keyswitch to the OFF position. Remove the wire short.
442 M0070030-01
Circuit Tests
Table 312
Open Circuit
4. Create an Open Between the Wires of the Suspect Com- Detected Result: A 2533-5, 2535-5, 1072-5, or a 1073-5 diagnostic
pression Brake Solenoid at the Valve Cover Connector code is active. The ECM detected the open at the valve cov-
er connector for the compression brake solenoid. The har-
To troubleshoot a 2533-6 or 1072-6 diagnostic code, use the ness wiring between the valve cover connector and the ECM
“ Compression Brake Low/High Override”” on the electronic is OK.
service tool. To troubleshoot a 2535-6 or 1073-6 diagnostic
code, use the “ Compression Brake Med/High Override”” on the Proceed to Test Step 5.
Result: A 2533-5, 2535-5, 1072-5, or a 1073-5 diagnostic
A. Turn the keyswitch to the OFF position. code is active. The ECM did not detect the open at the valve
cover connector for the compression brake solenoid.
B. Disconnect the harness at the valve cover connector.
Repair: Repair the harness or replace the harness between
C. Turn the keyswitch to the ON position. the P2 connector and the valve cover connector. Verify that
the problem is resolved.
D. Access the diagnostic override under the “Diagnostics” menu.
E. Start the override for the compression brake.
F. Once the electronic service tool displays the status of the com-
G. Monitor the active diagnostic code screen on the electronic

H. Turn the keyswitch to the OFF position. Remove the wire short.
I. Reconnect the valve cover connector.
M0070030-01 443
Circuit Tests
Table 313
Open Circuit
5. Create an Open Circuit at the Compression Brake Solenoid Detected Result: A 2533-5, 2535-5, 1072-5, or a 1073-5 diagnostic
code is active. The ECM detected the open at the valve cov-
Two solenoids are activated to create a medium braking ac- er connector for the compression brake solenoid. The har-
tion. The short could be in either solenoid or in the harness. ness wiring between the valve cover connector and the ECM
To isolate the problem for a medium braking action, run this is OK.
test step for each of the solenoids. The open must be created
separately at each solenoid. Repair: Replace the suspect compression brake solenoid.
To troubleshoot a 2533-6 or 1072-6 diagnostic code, use the Verify that the repair eliminates the problem.
“ Compression Brake Low/High Override”” on the electronic
service tool. To troubleshoot a 2535-6 or 1073-6 diagnostic Result: A 2533-5, 2535-5, 1072-5, or a 1073-5 diagnostic
code, use the “ Compression Brake Med/High Override”” on the code is active. The ECM did not detect the open at the com-
electronic service tool. pression brake solenoid. There is a short circuit between the
valve cover connector and the connector for the compres-
A. Turn the keyswitch to the OFF position. sion brake solenoid.
B. Remove the valve cover. Repair: Repair the harness or replace the harness between
the connector for the compression brake solenoid and the
C. Reconnect the valve cover connector. valve cover connector. Verify that the problem is resolved.
D. Disconnect the connector on the suspect compression brake

solenoid.
E. Inspect the terminals on the connector for the compression

brake solenoid for damage.
G. Access the diagnostic override under the “Diagnostics” menu.
H. Start the override for the compression brake.
I. Once the electronic service tool displays the status of the com-
Monitor the active diagnostic code screen on the electronic service

tool. Check and record any active diagnostic codes.
Turn the keyswitch to the OFF position.
444 M0070030-01
Circuit Tests
i06688798
SCR Catalyst Inlet Temperature

Sensor - Test
Table 314

PDL Code Comments
Code
The aftertreatment SCR catalyst intake gas temperature sensor has detected that
4360-16 E946 (2) Intake Gas Temperature : High -
the SCR intake temperature is above the normal operating range.

4360-17 E947 (1) Intake Gas Temperature : Low -
the SCR intake temperature is below the normal operating range.
least severe (1)

4360-18 E947 (2) Intake Gas Temperature : Low –
the SCR intake temperature is far below the normal operating range.
(1) Turbocharger (3) SCR inlet

(2) DPF (4) SCR outlet
The temperature of the exhaust gas is checked by

the SCR inlet temperature sensor (5) at the inlet of
the SCR canister (3). This input is used to ensure a
proper reaction with the SCR catalyst and to properly
dose DEF into the exhaust stream.
M0070030-01 445
Circuit Tests
(5) SCR inlet temperature sensor
446 M0070030-01
Circuit Tests
Table 315
1. Determine the diagnostic code. Diagnostic trouble Result : A 4360-16 or E946 (2) code with an ETI of 1 or 2
code is active or logged.
A. Connect the electronic service tool to the service tool con-
nector. Refer to Troubleshooting, “Electronic Service Tools”, if Proceed to Test Step 2.
necessary.
Result : A 4360-17, E947 (1), 4360-18, or E947 (2) code
B. Determine if a diagnostic trouble code is present. is logged or active.
2. Check the operation of the SCR catalyst inlet tempera- Sensor Result : The value of the SCR catalyst inlet temperature
ture 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 al-
low the sensor to rest in ambient air for 2 minutes. For a 4360-16 or E946 (2) code, proceed to Test Step 4.
B. Connect to the engine ECM by using the electronic service For a 4360-17, E947 (1), 4360-18, or E947 (2) code pro-
tool. ceed to Test Step 3.
C. Monitor the value of the SCR catalyst inlet temperature sen- Result : The value of the SCR catalyst inlet temperature
sor 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.
3. Check for exhaust leaks. Exhaust leaks Result : There were exhaust leaks found.
A. Start the engine. Repair : Repair or replace the component that is causing
an exhaust leak.
B. Check the exhaust system for proper installation.
C. Check for proper installation of the exhaust system
insulation.
D. Inspect the exhaust system between the DPF and the SCR
for signs of an exhaust leak.
E. Inspect the SCR inlet temperature sensor to ensure proper

installation in the sensor port.
(continued)
M0070030-01 447
Circuit Tests
(Table 315, contd)

4. Check the Diesel Exhaust Fluid (DEF) quality. DEF Result : The DEF is not contaminated.
A. Measure the DEF quality. Refer to the Systems Operation, Repair : Check the exhaust system for fuel. Refer to Trou-
Testing and Adjusting, “Diesel Exhaust Fluid Quality - Test” for bleshooting, “Exhaust System Contains Fuel”.
Contact the Dealer Solution Network (DSN) for authoriza-
tion to replace the DOC, DPF, DEF Injector, and the SCR
catalyst.
Repair : Contact the DSN for authorization to replace the

DEF tank, DEF tank header and filters, all DEF lines, DEF
pump, DEF injector, and the SCR catalyst.
5. Perform the “ Aftertreatment System Functional Test”” “Aftertreatment Result : The test was successful.
System Functional
A. Start the engine. Test” Return the unit to service.
B. Connect to the “Engine #1 Aftertreatment Control ECM” us- Result : The test was not successful. There are additional
ing the electronic service tool. diagnostic codes.
C. Perform the “Aftertreatment System Functional Test” . Repair : Troubleshoot the diagnostic codes that are active.
Refer to the Troubleshooting guide for the correct trouble-
shooting procedure.
Verify that the problem has been resolved.
Complete the procedure in the order in which the If a signal voltage is close to the reference voltage,
steps are listed. the ECM will internally adjust the signal voltage. The
internal adjustment causes the pressure value for the
i06688804 sensor to be correct. This process is called automatic
sensor calibration.
Sensor Calibration Required - If a signal voltage is not close to the reference
Test voltage, the ECM will not internally adjust the signal
voltage. The ECM will set a fault code that indicates
there is a problem with the signal voltage.
During normal operation, each pressure sensor Table 316 indicates the maximum error that is
permitted for each sensor, and the reference for that
outputs a signal voltage that accurately represents sensor. Refer to the troubleshooting procedure to
the pressure that is sensed by the sensor. However, determine the root cause of the incorrect signal
certain circuit conditions can cause a signal voltage voltage.
to become inaccurate.
During each key on event of at least 2 seconds, the
Electronic Control Module (ECM) evaluates the
signal voltage from each pressure sensor. The ECM
compares each signal voltage to a reference voltage.
The reference voltage that is used depends on the
sensor.
448 M0070030-01
Circuit Tests
Table 316
Code Description
During key on, the signal voltage from the crankcase air pressure
Crankcase Air Pressure Sensor : Out of sensor indicated a crankcase air pressure greater than +/- 1.5 kPa
101-13 101-13
Calibration (0.2 psi).
There is not a reference sensor for this sensor
During key on, the signal voltage from the EGR differential pressure
EGR Differential Pressure Sensor : Out sensor indicated a differential pressure greater than +/- 11 kPa
411-13 3387-13
of Calibration (2 psi).
During key on, the signal voltage from the diesel particulate filter #1
differential pressure sensor indicated a dpf differential pressure
greater than +/- 2 kPa (0.3 psi).
DPF #1 Differential Pressure Sensor :
3251-13 2458-13 The 2458-13 will not activate for several hours if the ambient tem-
Out of Calibration
perature is below 7° C (45° F) or if active regeneration has not been
performed.
During key on, the signal voltage from the EGR intake pressure
EGR Intake Pressure Sensor : Out of sensor indicated an EGR intake pressure greater than +/- 18 kPa
3358-13 3385-13
Calibration (3 psi) from the atmospheric pressure sensor.
Reference sensor : Atmospheric Pressure Sensor
During key on, the signal voltage from the Intake Manifold pressure
Intake Manifold Pressure Sensor : Out sensor indicated an Intake Manifold pressure greater than +/-
3563-13 1785-13
of Calibration 18 kPa (3 psi) from the Atmospheric Pressure sensor.
During key on, the signal voltage from the diesel particulate filter #1
DPF #1 Intake Pressure Sensor : Out of intake pressure sensor indicated a dpf intake pressure greater than
3609-13 3464-13
Calibration +/- 6 kPa (1 psi) from the atmospheric pressure sensor.
During key on, the signal voltage from the aftertreatment #1 secon-
Aftertreatment #1 Secondary Air Pres- dary air pressure sensor indicated a secondary air pressure greater
3837-13 3493-13
sure Sensor : Calibration Required than +/- 12 kPa (2 psi) .from the atmospheric pressure sensor.

steps are listed.
M0070030-01 449
Circuit Tests
Table 317
1. Check for Diagnostic Trouble Codes Diagnostic Result: There is an active or there is a logged -13 code.
Trouble
The engine coolant temperature must be greater than 0° C (32° F) Codes Proceed to Test Step 2.
before beginning this procedure.

and the Electronic Control Module (ECM) . Refer to Troubleshoot-
B. Wait at least 30 seconds in order for the diagnostic codes to be-

come active.
Look for an active -13 code or for a logged -13 code.
2. Check for Debris Debris Result: The sensor measurement port is not blocked by
debris.
B. Check the suspect sensor for debris.
Result: A -13 code is not present, return the unit to service.
C. If applicable, check the reference sensor for debris.
Result: A -13 code is present, replace the suspect sensor.
D. Check the sensor measurement port for blockage by debris. Verify that the problem is resolved.
E. If debris is found, clear the debris from the measurement port Result: If more than one -13 code is present and the codes
and replace the suspect sensor. have a reference sensor, replace the reference sensor. Verify
that the problem is resolved.
G. Check for -13 codes. Wait at least 30 seconds in order for the di-
agnostic codes to become active.
The 2458-13 will not activate for several hours if the ambient tem-
perature is below 7° C (45° F) or if active regeneration has not
been performed. If troubleshooting a 2458-13 and ambient temper-
ature is below 7° C (45° F), perform a "Manual DPF regeneration"
after completing the repair to verify that the problem has been
resolved.
3. Inspect the Suspect Sensor Connector Moisture Result: The suspect sensor connector has moisture and/or
corrosion.
Inspect the suspect sensor connector for moisture and/or
corrosion. Result: The suspect sensor connector does not have mois-
ture and/or corrosion.
(continued)
450 M0070030-01
Circuit Tests
(Table 317, contd)

4. Remove any moisture and/or corrosion Moisture Result: A -13 code is not present, return the unit to service.
A. Disconnect the suspect sensor connector. Result: A -13 code is present, replace the suspect sensor.
B. Remove any moisture and/or corrosion from the outside of the
connector. Check for moisture and corrosion inside the connector. Result: If only a 289-13 code is present, replace the refer-
Verify that the seals for the wires are sealing correctly. Refer to ence sensor. Verify that the problem is resolved.
Troubleshooting, “Electrical Connectors - Inspect”, if necessary.
Result: If only a 460-13 or (5580 -13) code is present, re-
C. If necessary, repair the connector or replace the connector. place the reference sensor. Verify that the problem is
resolved.
D. Reconnect the connector. Verify that the connection is secure.
Result: If more than one -13 code is present and the codes
E. Turn the keyswitch to the ON position. have a reference sensor, replace the reference sensor. Verify
F. Monitor the diagnostic codes on the electronic service tool.
Check for -13 codes. Wait at least 30 seconds in order for the diag-
nostic codes to become active.
ature is below 7° C (45° F), perform a “Manual DPF regeneration”
resolved.
5. Check for Moisture and/or Corrosion in the Circuit Moisture Result: A -13 code is not present, return the unit to service.
A. Check all the connectors in the circuit for moisture and/or Result: A -13 code is present, replace the suspect sensor.
corrosion. Verify that the problem is resolved.
B. Check for corrosion inside the connector. Verify that the seals Result: If only a 460-13 or 5580 -13 code is present, replace
for the wires are sealing correctly. Refer to Troubleshooting, “Elec- the reference sensor. Verify that the problem is resolved.
trical Connectors - Inspect”, if necessary.
Result: If more than one -13 code is present and the codes
C. If necessary, repair the connector or replace the connector. have a reference sensor, replace the reference sensor. Verify
D. Reconnect the connector. Verify that the connection is secure.
F. Monitor the diagnostic codes on the electronic service tool.

Check for -13 codes. Wait at least 30 seconds in order for the diag-
nostic codes to become active.
ature is below 7° C (45° F), perform a “Manual DPF regeneration”
resolved.
M0070030-01 451
Circuit Tests
i06917978
Sensor (Data Link Type) - Test

system if a problem is suspected with the CAN data
link . Also use this procedure if a diagnostic code in
Table 318 is active or easily repeated.
Table 318
Code Description
Aftertreatment #1 Intake NOx : The aftertreatment intake NOx sensor heater cannot generate
3216-11 3655-11
Other Failure Mode enough heat or the power supply is intermittent.
Aftertreatment #1 Intake NOx :

3216-12 3655-12 A failed aftertreatment intake NOx sensor has been detected.
Failure
Aftertreatment #1 Outlet NOx : The aftertreatment outlet NOx sensor heater cannot generate
3226-11 3609-11
Other Failure Mode enough heat or the power supply is intermittent.
Aftertreatment #1 Outlet NOx :

3226-12 3609-12 A failed aftertreatment outlet NOx sensor has been detected.
Failure
Aftertreatment 1 Diesel Exhaust A Diesel Exhaust Fluid Controller (DCU) has been flashed or a
3360-12 3820-12
Fluid Controller : Failure failed DCU has been detected.
Aftertreatment #1 DEF Concen-
The DEF quality sensor is unable to read the DEF concentration
3516–2 3100–2 tration: Erratic, Intermittent, or
due to an optical path obstruction.
Incorrect
Aftertreatment #1 DEF Concen-
3516–12 3100–12 A failed DEF Quality Sensor has been detected
tration: Failure
Note: Turn the keyswitch to the OFF position before “The version of the ECM is not recognized and the
connecting or disconnecting these components. integrity of the changed parameters and displayed
data is not guaranteed.”
If the electronic service tool will not communicate
with the ECM, refer to Troubleshooting, “Electronic This message indicates that one of the following
Service Tool Does Not Communicate” before you conditions exist:
begin this procedure. The procedure verifies that
electrical power is being supplied to the ECM and to • The flash file in the ECM is newer than the version
the service tool connector. of the electronic service tool.
The data links are used to communicate information • The latest version of the electronic service tool has
between the engine ECM and other control modules not been installed.
that are a part of the application. The electronic
service tool also communicates with the ECM via the
data links.
The service tool 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 this problem, 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:
452 M0070030-01
Circuit Tests
M0070030-01 453
Circuit Tests
Note: The DEF Quality Sensor is only available on

2017models or later.
steps are listed.
Table 319
Connectors
1. Check the Connectors Result: The connectors were connected properly and did
not have corrosion or moisture.
If a -11 code is active or logged, Proceed to Test Step 2.
B. Connect to the “Engine #1 Aftertreatment Controller” using the
electronic service tool. If a 3360-12 (3820-12) code is active or logged, Proceed
to Test Step 3.
C. Record all active and logged codes.
If a 3216-12 (3655-12) or 3226-12 (3609-12) code is ac-
D. Turn the keyswitch to the OFF position. tive or logged, replace the appropriate NOx sensor. Refer
to Disassembly and Assembly, Nitrogen Oxide Sensor -
E. Allow the system to completely power down before disconnect- Remove and Install for special handling instructions. Pro-
ing connectors. ceed to Test Step 4.
F. Thoroughly inspect the connectors that are associated with the Result: A 3516–12 (3100–12) code is active or logged.
data link circuits. Verify that the connectors are free of debris, free
of corrosion, and securely connected. Repair: Replace the DEF tank header. Refer to the ap-
propriate Disassembly and Assembly for removal and in-
stallation instructions.
Result: A 3516–2 (3100–2) code is active or logged.
Result: The connectors were not connected properly or

the connectors did have corrosion or moisture.
Repair: Repair the connectors and/or the wiring. Replace

parts, if necessary. The DCU connector is not service-
able. Verify that the original problem is resolved.
Battery Voltage
2. Check the Voltage to the Suspect Sensor. Result: The measured voltage is equal to battery voltage.
A. Disconnect the suspect sensor from the wiring harness. Repair: Replace the failed NOx Sensor.
C. Measure the voltage between battery “SUPPLY” and “RE- Result: The measured voltage is not equal to battery
TURN” on the wiring harness connector of the suspect sensor. voltage.
Repair: There is a problem with an intermittent battery

supply. Check the power supply to the suspect sensor.
(continued)
454 M0070030-01
Circuit Tests
(Table 319, contd)

Test Completed
3. Perform the DEF Dosing Control Module Reset Successfully Result: The test completed successfully and a 3360-12
(3820-12) code is no longer active.
B. Connect to the “Engine #1 Aftertreatment Controller” using the
electronic service tool. Result: The test did not complete successfully and a
3360-12 (3820-12) code is still active.
C. Perform the “DEF Dosing Control Module Reset” .
Repair: Replace the DCU.
4. Inspect the DEF Quality Sensor DEF Quality Result: Debris was found in the DEF tank, DEF header
Sensor manifold filter, or the DEF quality sensors.
A. Remove the DEF tank header from the DEF tank.
Repair: Flush the DEF tank and replace all the DEF fil-
B. Inspect the DEF tank and DEF manifold filter for debris. ters. Refer to the Testing and Adjusting, Diesel Exhaust
Fluid Tank - Flush procedure.
C. Inspect the DEF quality sensor for visible debris. Refer to the
Testing and Adjusting, Diesel Exhaust Fluid Tank - Flush Proceed to Test Step 5.
procedure.
Result: No debris was found or a DEF quality sensor is
damaged.
Repair: Replace the DEF tank header assembly and fill

the tank with DEF that meets ISO 22241 quality
standards.
Test Completed
5. Perform the Aftertreatment System Functional Test. Successfully Result: No faults came active.
A. Turn the keyswitch to the ON position. Return the unit to service.
B. Start the engine. Result: A fault came active.
C. Connect to the “Engine #1 Aftertreatment Controller” using the Repair: Troubleshoot the fault that became active during
electronic service tool. the “Aftertreatment System Functional Test” . After the is-
sue has been resolved, run the “Aftertreatment System
D. Perform the “Aftertreatment System Functional Test” . Functional Test” again.
i06691102
Sensor Signal (Analog, Active)

- Test

system if a problem is suspected with the sensors.
Also use this procedure if any one of the diagnostic
codes in Table 320 is active or easily repeated.
M0070030-01 455
Circuit Tests
Table 320

The Electronic Control Module (ECM) detects signal voltage
Engine Oil Pressure Sensor that is not in the acceptable range.
100-3 100-3
: Voltage Above Normal The code is logged.
The value of the parameter is set to a gauge pressure.
The ECM detects signal voltage that is not in the acceptable

Engine Oil Pressure Sensor range.
100-4 100-4
: Voltage Below Normal The code is logged.

Crankcase Air Pressure
range.
101-3 101-3 Sensor : Voltage Above
The code is logged.
Normal

Crankcase Air Pressure
range.
101-4 101-4 Sensor : Voltage Below
The code is logged.
Normal

Atmospheric Pressure Sen- range.
108-3 3528-3
sor : Voltage Above Normal The code is logged.

Atmospheric Pressure Sen- range.
108-4 3528-4
sor : Voltage Below Normal The code is logged.

range.
Engine Coolant Pressure :
Refer to the machine schematic for wiring and pinout
information.

range.
Engine Coolant Pressure :
information.

Fuel Rail Pressure Sensor : range.
157-3 1797-3
Voltage Above Normal The code is logged.
(continued)
456 M0070030-01
Circuit Tests
(Table 320, contd)


Fuel Rail Pressure Sensor : range.
157-4 1797-4
Engine Exhaust Gas Recir- The ECM detects signal voltage that is not in the acceptable
culation Differential Pres- range.
411-3 3387-3
sure Sensor : Voltage The code is logged.
Above Normal The value of the parameter is set to a gauge pressure.
Engine Exhaust Gas Recir- The ECM detects signal voltage that is not in the acceptable
culation Differential Pres- range.
411-4 3387-4
sure Sensor : Voltage Below The code is logged.
Normal The value of the parameter is set to a gauge pressure.

Turbocharger #1 Compres-
range.
1176-3 2738-3 sor Inlet Pressure Sensor :
The code is logged.

Turbocharger #1 Compres-
range.
1176-4 2738-4 sor Inlet Pressure Sensor :
The code is logged.

Auxiliary Pressure Sensor : range.
1387-3 1835-3
Voltage Above Normal The code is logged.

Auxiliary Pressure Sensor : range.
1387-4 1835-4
(continued)
M0070030-01 457
Circuit Tests
(Table 320, contd)


Engine Intake Valve Actua-
range.
2948-3 1924-3 tion System Oil Pressure :
The code is logged.

Engine Intake Valve Actua-
range.
2948-4 1924-4 tion System Oil Pressure :
The code is logged.
DPF #1 Intake Temperature

The code is logged.
The ECM detects voltage that is not in the acceptable range.
Normal
DPF #1 Intake Temperature

The code is logged.
The ECM detects voltage that is not in the acceptable range.
Normal

DPF #1 Differential Pres-
range.
3251-2 2458-2 sure Sensor : Erratic, Inter-
The code is logged.
mittent, or Incorrect

range.
3251-3 2458-3 sure Sensor : Voltage
The code is logged.
Above Normal

range.
3251-4 2458-4 sure Sensor : Voltage Below
The code is logged.
Normal
(continued)
458 M0070030-01
Circuit Tests
(Table 320, contd)


EGR Intake Pressure Sen- range.
3358-3 3385-3

EGR Intake Pressure Sen- range.
3358-4 3385-4

ARD Fuel Pressure #1 Sen- range.
3480-3 2460-3

3480-4 2460-4

Intake Manifold Pressure
range.
The code is logged.
Normal

Intake Manifold Pressure
range.
The code is logged.
Normal

DPF #1 Intake Pressure
range.
The code is logged.
Normal
(continued)
M0070030-01 459
Circuit Tests
(Table 320, contd)


DPF #1 Intake Pressure
range.
The code is logged.
Normal

Aftertreatment #1 Secon-
range.
3837-3 3493-3 dary Air Pressure Sensor :
The code is logged.

Aftertreatment #1 Secon-
range.
3837-4 3493-4 dary Air Pressure Sensor :
The code is logged.

4077-3 2497-3

4077-4 2497-4
Aftertreatment #1 SCR Cat- The ECM detects signal voltage that is not in the acceptable
4360-3 3105-3 alyst Intake Gas Tempera- range.
ture : Voltage Above Normal The code is logged.
Aftertreatment #1 SCR Cat- The ECM detects signal voltage that is not in the acceptable
4360-4 3105-4 alyst Intake Gas Tempera- range.
ture : Voltage Below Normal The code is logged.
(continued)
460 M0070030-01
Circuit Tests
(Table 320, contd)


Fuel Pressure Sensor - Be-
range.
5578-3 289-3 fore Fuel Filter : Voltage
The code is logged.
Above Normal

Fuel Pressure Sensor - Be-
range.
5578-4 289-4 fore Fuel Filter : Voltage Be-
The code is logged.
low Normal

Fuel Pressure Sensor -
range.
5580-3 460-3 After Fuel Filter : Voltage
The code is logged.
Above Normal

Fuel Pressure Sensor -
range.
5580-4 460-4 After Fuel Filter : Voltage
The code is logged.
Below Normal
The supply voltage is routed to terminal 1 of each

sensor connector. The sensor return is routed to
terminal 2 of each sensor connector. The sensor
signal is routed to terminal 3 of each sensor
connector. The ECM provides short circuit protection
for the internal power supply. A short circuit to the
battery will not damage the internal power supply.
Diagnostics on the electronic service tool
Wiggle Test – The Wiggle Test allows you to monitor
the status of the signals from the sensors.
For additional information regarding the Wiggle Test,

refer to the documentation that accompanies the
electronic service tool software.
M0070030-01 461
Circuit Tests
Note: The diagram above is a simplified schematic of

the electrical circuit. The schematic is electrically
correct. However, not all the possible harness
connectors are shown. Refer to the latest revision of
the Electrical Schematic for the complete schematic.
Note: If a sensor is not listed in the above schematic,

Refer to the application schematic for wiring and
pinout information.
462 M0070030-01
Circuit Tests
Locations of the sensors and the sensor connectors
Note: If a sensor is not listed in the above schematic,

information.
M0070030-01 463
Circuit Tests
Illustration 172 g02110736 Illustration 174 g02110739

(1) Fuel rail pressure sensor (3) NRS differential pressure sensor
(4) NRS absolute pressure sensor

(2) Intake manifold pressure sensor
(5) Atmospheric pressure sensor
464 M0070030-01
Circuit Tests

(6) Crankcase pressure sensor (8) Fuel pressure sensor at the inlet of the tertiary filter
(9) Fuel pressure sensor at the outlet of the tertiary filter

(7) Oil pressure sensor
CEM (typical)
(1) Absolute pressure sensor for the DPF
M0070030-01 465
Circuit Tests

CEM (typical)
(1) Combustion air absolute pressure sensor
(2) Main fuel pressure sensor
(3) Pilot fuel pressure sensor
Table 321
1. Check for Diagnostic Codes Diagnostic Result: A -3 diagnostic code is active.

code
the ECM . Refer to Troubleshooting, “Electronic Service Tools”, if
necessary. Result: A -4 diagnostic code is active.
C. Look for -3 or -4 active or logged codes: Result: A 2458-2 or 3251-2 diagnostic code is active.
2. 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. Use a jumper wire to create a short between terminal 3 (signal)
and terminal 2 (sensor return) at the sensor connector. The wiring is OK. Replace the sensor.
Result: A -4 diagnostic code does not become active
C. Monitor the diagnostic codes on the electronic service tool. Check for the suspect sensor.
for an active -4 diagnostic code for the suspect sensor.
D. Turn the keyswitch to the OFF position.
(continued)
466 M0070030-01
Circuit Tests
(Table 321, contd)

3. Create an Open at the Suspect Sensor Connector Create an Result: A -3 diagnostic code became active after dis-
Open connecting the sensor.
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 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
Connect the sensor and then proceed to Test Step 5
B. Measure the voltage between pin 1 and pin 2 at the suspect
sensor. Result: The supply voltage is not approximately 5.0 ±
0.2 VDC.
There is a short in the harness to the battery. Repair the

wiring or replace the harness

STOP
5. 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”.
3. Damaged that is caused by excessive heat If the wiring looks OK, perform the following procedure.
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
M0070030-01 467
Circuit Tests
(1) Differential pressure lines
468 M0070030-01
Circuit Tests
Table 322
6. Inspect the DPF Differential Pressure Lines inspected Result: The DPF differential pressure lines,
Lines, Fittings, and Manifold fittings, and manifold are connected and free
from obstructions.
A. Ensure that the DPF differential pressure
lines are connected. Proceed to Test Step 7
B. Ensure that the DPF differential pressure Result: The DPF differential pressure lines
lines, fittings, and manifold are free from ob- are not connected or the lines, fittings, and
structions. Make sure that moisture has not fro- manifold have obstructions.
zen in the lines, fittings, and manifold.
Repair or replace the DPF differential pres-
Note: The 2458-2 or 3251-2 will not activate for sure line. Clear all codes. Return the engine
several hours if the ambient temperature is be- to service.
low 7° C (45° F) or if active regeneration has STOP
not been performed. If troubleshooting a 2458-
2 or 3251-2 and ambient temperature is below
7° C (45° F), perform a “Manual DPF regenera-
tion” after completing the repair to verify that
7. Inspect the Electrical Connectors for the Connectors inspected Result: A 2458-2 or 3251-2 diagnostic code
ARD Pilot Fuel Pressure Sensor and the will appear when the connectors are switched
DPF Differential Pressure Sensor between sensors, be certain the connectors
are connected to the correct sensors.
A. Check the connectors for the differential
pressure sensor and the pilot fuel pressure Connect the connectors to the correct sen-
sensor to ensure that the connectors are con- sors. Verify that the problem is resolved.
nected to the proper sensor. Clear all codes. Return the engine to service.
Note: The 2458-2 or 3251-2 will not activate for STOP

several hours if the ambient temperature is be-
low 7° C (45° F) or if active regeneration has
not been performed. If troubleshooting a 2458-
2 or 3251-2 and ambient temperature is below
7° C (45° F), perform a “Manual DPF regenera-
tion” after completing the repair to verify that
i06691215
Sensor Signal (Analog,

Passive) - Test

system if a problem is suspected with a sensor. Use
this procedure if any one of the diagnostic codes in
Table 323 is active or easily repeated.
M0070030-01 469
Circuit Tests
Table 323

110-3 110-3 Engine Coolant Temperature Sen- The code is logged if the engine
sor : Voltage Above Normal has been running for more than 7
minutes and an open circuit has
been detected.
110-4 110-4 Engine Coolant Temperature Sen- The code is logged. The ECM de-
sor : Voltage Below Normal tects voltage that is not in the ac-
ceptable range.
171-3 171-3 Ambient Air Temperature : Voltage The code is logged. The ECM de-
Above Normal tects voltage that is not in the ac-
ceptable range.
171-4 171-4 Ambient Air Temperature : Voltage The code is logged. The ECM de-
Below Normal tects voltage that is not in the ac-
ceptable range.
172-3 2526-3 Air Inlet Temperature Sensor : Volt- The code is logged.
age Above Normal The ECM detects voltage that is
not in the acceptable range.
172-4 2526-4 Air Inlet Temperature Sensor : Volt- The code is logged.
age Below Normal The ECM detects voltage that is
174-3 174-3 Fuel Temperature Sensor : Voltage The code is logged. The ECM will
Above Normal flag the fuel temperature as inva-
lid data and the fuel temperature
174-4 174-4 Fuel Temperature Sensor : Voltage
is set to a default value of 40 °C
Below Normal
(104 °F).
175-3 175-3 Engine Oil Temperature Sensor : The code is logged. The ECM de-
Voltage Above Normal tects voltage that is not in the ac-
ceptable range.
175-4 175-4 Engine Oil Temperature Sensor : The code is logged. The ECM de-
Voltage Below Normal tects voltage that is not in the ac-
ceptable range.
412-3 3386-3 EGR Temperature Sensor : Volt- The code is logged.

age Above Normal The ECM detects voltage that is
412-4 3386-4 EGR Temperature Sensor : Volt- The code is logged.

age Below Normal The ECM detects voltage that is
441-3 1836-3 Auxiliary Temperature 1 : Voltage The code is logged. The ECM will
Above Normal flag the temperature as invalid
data and the temperature is set to
a default value.
Below Normal flag the temperature as invalid
a default value.
Above Normal flag the temperature as invalid
a default value.
(continued)
470 M0070030-01
Circuit Tests
(Table 323, contd)


Below Normal flag the temperature as invalid
a default value.
1385-3 1836-3 Auxiliary Temperature Sensor : The code is logged. The ECM will
Voltage Above Normal flag the temperature as invalid
a default value.
1385-4 1836-4 Auxiliary Temperature Sensor : The code is logged. The ECM will
Voltage Below Normal flag the temperature as invalid
a default value.
2630-3 3372-3 Engine Charge Air Cooler #1 Out- The code is logged.
let Temperature Sensor : Voltage The ECM detects voltage that is
Above Normal not in the acceptable range.
2630-4 3372-4 Engine Charge Air Cooler #1 Out- The code is logged.
let Temperature Sensor : Voltage The ECM detects voltage that is
Below Normal not in the acceptable range.
System Overview
The sensor signal for the passive sensor is routed
from the ECM to terminal 1 of each sensor connector.
The sensor return for the passive sensors is routed to
the ECM from terminal 2 of each sensor connector.
Diagnostics on the electronic service tool
Wiggle Test – The Wiggle Test allows you to monitor
the status of the signals from the sensors.
For additional information regarding the Wiggle Test,

refer to the documentation that accompanies the
electronic service tool software.

Terminal locations at the connector for the passive
analog sensors
(Terminal 1) Sensor signal
(Terminal 2) Analog sensor return
M0070030-01 471
Circuit Tests

steps are listed.
472 M0070030-01
Circuit Tests
Table 324
1. Check for Diagnostic Trouble Codes Codes Result: A -3 diagnostic code is active.
A. Connect to the electronic service tool. Proceed to Test Step 2.
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 3.
Result: For a diagnostic code that is logged but not cur-
Wait at least 30 seconds in order for the diagnostic codes rently active, Proceed to Test Step 4.
to become active. Note: If a 412-3 or 3386–3 code is logged, operate the en-
gine until normal operating temperature is reached. Use the
D. Look for these active codes or logged codes: electronic service tool to check if the 412-3 or 3386–3 code
is now active. If the 412-3 or 3386–3 code is now active, pro-
1.-3 ceed to Test Step 2.
2. -4
2. Create a Short at the Sensor Connector Short circuit Result: The -3 diagnostic code remains active for the sus-
recognized pect sensor.
A. Turn the keyswitch to the OFF position. There is an open circuit in the harness.
B. Disconnect the suspect sensor. Repair: Repair the wiring or replace the harness.
C. Install the jumper wire between terminal 1 (sensor signal) Verify that the problem is resolved.
and terminal 2 (sensor return) at the sensor connector.
Result: A -4 diagnostic code became active after creating
D. Turn the keyswitch to the ON position. the short at the sensor connector.
The wiring is OK.
E. Monitor the diagnostic codes on the electronic service tool.
Check for an active -4 diagnostic code for the suspect sensor. Repair: Replace the sensor.
Wait at least 30 seconds in order for the diagnostic codes Verify that the problem is resolved.
to become active.
(continued)
M0070030-01 473
Circuit Tests
(Table 324, contd)
3. Create an Open at the Suspect Sensor Connector Open circuit Result: The -4 diagnostic code remains active for the sus-
recognized pect sensor.
A. Turn the keyswitch to the OFF position. There is an open circuit in the harness.
B. Disconnect the sensor connector of the suspect sensor with Repair: Repair the wiring or replace the harness.
the active -4 diagnostic code.
Result: A -3 diagnostic code became active after discon-
D. Monitor the diagnostic codes on the electronic service tool. necting the sensor.
Check for an active -3 diagnostic code for the suspect sensor. The wiring is OK.
Wait at least 30 seconds in order for the diagnostic codes Repair: Replace the sensor.
to become active.
· A 412-3 or 3386–3 code will not become active during Verify that the problem is resolved.
“ Cold Mode”” . Run the engine to exit cold mode before
troubleshooting a 412-3 code.
· 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.
Wiggle test
4. Perform the Wiggle Test Result: The wiring failed the Wiggle Test.
There is a problem with the wiring.
Carefully following this procedure is the best way to identify
the root cause of an intermittent problem. Repair: Repair the wiring or replace the wiring.
Note: To troubleshoot a 412-3 or 3386–3 diagnostic code the Verify that the problem is resolved.
engine must be operated until normal operating temperature is
reached. Result: The wiring passed the Wiggle Test.
A. Turn the keyswitch to the ON position. Repair: The problem may be intermittent. Inspect the wiring.
Refer to Troubleshooting, “Electrical Connectors - Inspect”.
B. Use the electronic service tool to run the “Wiggle Test” .
If the wiring looks OK, perform the following procedure.
C. Slowly wiggle the wiring and the connectors between the
P2 connector and the sensor. Slowly wiggle the wiring and the 1. Turn the keyswitch to the OFF position.
connectors between the P1 connector and the sensor. Pay
particular attention to the wiring near each connector. Be sure 2. Disconnect the connectors. Carefully inspect the terminals
to wiggle all the wiring. for proper installation. Make sure that each terminal is clean
and dry.
D. As you wiggle the wiring look for these problems.
3. Insert a pin into each socket. Verify that each socket grips
1. Loose connectors or damaged connectors the pin firmly. Repair any problems.
3. Damage that is caused by excessive heat 4. Connect all connectors.
5. Improper routing of wiring 5. Verify that the problem is resolved.
6. Return the unit to service.
474 M0070030-01
Circuit Tests
i06691712
Sensor Supply - Test

system if a problem is suspected with a sensor
supply. Use this procedure if any one of the
diagnostic codes in Table 325 is active or easily
repeated.

Table 325
Atmospheric Pressure Sensor : Da- The code is logged.

108-21 3528-21
ta Drifted Low The 5 VDC supply to the sensor has been lost.
8 VDC Supply : Voltage Above

Normal
8 VDC Supply : Voltage Below
Normal
EGR Intake Pressure Sensor : Da- The code is logged.

3358-21 3385-21
ta Drifted Low The 5 VDC supply to the sensor has been lost.
5 Volt Sensor DC Power Supply : The code is logged.

3509-3 262-3
Voltage Above Normal All sensors are set to default values.
5 Volt Sensor DC Power Supply : The code is logged.

3509-4 262-4
Voltage Below Normal All sensors are set to default values.
5 v Sensor DC Power Supply #2 : The code is logged.

3510-3 2131-3
Voltage Above Normal Engine power may be derated.
5 v Sensor DC Power Supply #2 : The code is logged.

3510-4 2131-4
Voltage Below Normal Engine power may be derated.
Intake Manifold Pressure Sensor : The code is logged.

3563-21 1785-21
Data Drifted Low The 5 VDC supply to the sensor has been lost.
DPF #1 Intake Pressure Sensor : The code is logged.

3609-21 3464-21
Data Drifted Low The 5 VDC supply to the sensor has been lost.
Aftertreatment #1 Secondary Air The code is logged.

3837-21 3493-21
Pressure Sensor : Data Drifted Low The 5 VDC supply to the sensor has been lost.
Fuel Pressure Sensor - Before Fuel The code is logged.

5578-21 289-21
Filter : Data Drifted Low The 5 VDC supply to the sensor has been lost.
Fuel Pressure Sensor - After Fuel The code is logged.

5580-21 460-21
Filter : Data Drifted Low The 5 VDC supply to the sensor has been lost.
System Operation The supply voltage for the sensors is routed from the
ECM to terminal 1 of each sensor connector. The
The Electronic Control Module (ECM) supplies a sensor return for the sensors is routed from the ECM
regulated voltage of 5.0 ± 0.2 VDC to the sensors. to terminal 2 of each sensor connector. The ECM
provides short circuit protection for the internal power
supply. A short circuit to the battery will not damage
the internal power supply.
M0070030-01 475
Circuit Tests
Note: The sensors are not protected from

overvoltage. A short from the supply line to the
+Battery may damage the sensors. If any of the
diagnostic codes are active, a sensor may have been
damaged. Repair the sensor supply and check for
any active sensor diagnostic codes to determine if a
sensor has been damaged.

Sensor connector
(1) 5 V or 8 V sensor supply
(2) Sensor return
(3) Signal
Table 326
Sensor Supply Sensor Supply ECM Location
Sensor Supply #1 Sensors on A4:E4 engine ECM J2 connector or A5:E2 aftertreatment

controller J2 connector
Sensor Supply #2 Sensors on A4:E4 engine ECM J1 connector
476 M0070030-01
Circuit Tests
Note: The diagram above is a simplified schematic of

the ECM - relay circuit. The schematic is electrically
correct. However, not all the possible sensors or
harness connectors are shown. Refer to the latest
revision of the Electrical Schematic for the complete
schematic for your application.
steps are listed.
M0070030-01 477
Circuit Tests
Table 327
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 ECM is reporting the active sensor supply code.
Result: A -21 code is present.
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 while 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.
Verify that the repair resolved the problem.
3. Check the Sensor Supply Diagnostic Result: A -4 code is activated on the suspect sensor supply.
Codes
A. Turn the keyswitch to the OFF position. Remove the sensor. Check the sensor passage for a block-
age or obstruction. Also, check for moisture frozen in the
B. Unplug the suspect sensor from the wiring harness. lines.
C. Place a jumper wire between pin 1 and pin 2 on the suspect Repair: If blockage is not found, replace the sensor.
sensor wiring harness connector.
D. Connect to the electronic service tool.
Result: A -4 code is not activated on the suspect sensor
E. Turn the keyswitch to the ON position. supply.
F. Monitor the diagnostic codes using the electronic service tool. Repair: The problem is in the wiring from the ECM to the
sensor connector. Repair the wiring or replace the wiring.
i06691742
Shutdown (Ground Level) -

Test
Use this procedure to troubleshoot a suspected

problem with the ground level shutdown switch. Use
this procedure if a diagnostic code in Table 328 is
active or easily repeated.

478 M0070030-01
Circuit Tests
Table 328

If both contacts from the ground level shutdown switch change to
Remote Shutdown Input : Volt-
4215-3 267-3 the same state and the engine is running, the engine will continue
age Above Normal
to run. The code is logged.
If both contacts from the ground level shutdown switch change to

Remote Shutdown Input : Volt-
4215-4 267-4 the same state and the engine is running, the engine will continue
age Below Normal
to run. The code is logged.
The inputs from the ground level shutdown switch to the ECM
4215-31 E678 (1) Ground Level Shutdown have changed states.
The engine will shut down. The code is logged.
The shutdown switch will shut down the engine. The

engine ECM remains active. The electronic service
tool can be used to communicate with the ECM. The
shutdown switch must be returned to the RUN
position before the ECM will allow the engine to start.
The ECM reads the position of the shutdown switch.
If the engine is running, the ECM disables the fuel
injection. The status screen will display “Injection
Disabled” and “Remote Shutdown” .

Schematic

steps are listed.
M0070030-01 479
Circuit Tests
Table 329
1. Determine the Diagnostic Code Diagnostic Result: A E678 or 4215-31 diagnostic code is active.
Trouble
A. Establish communication between the electronic service tool Codes Proceed to Test Step 2.
and the ECM . Refer to Troubleshooting, “Electronic Service Tools”,
if necessary. Result: A 267-3 or 4215-3 diagnostic code is active.
B. Observe the “Active Diagnostic” screen on the electronic service Proceed to Test Step 3.
tool. Wait at least 30 seconds so that any codes may become
active. Result: A 267-4 or 4215-4 diagnostic code is active.
C. Look for these codes: Proceed to Test Step 4.
·E678 or 4215-31
·267-3 or 4215-3
·267-4 or 4215-4
2. Check the Status of the Shutdown Switch on the Electronic Switch Result: The status of the shutdown switch changed states
Service Tool Status after returning the shutdown switch to the RUN position.
A. Activate the shutdown. The shutdown switch is operating correctly.
B. Use the electronic service tool to verify that the engine rpm is 0. Result: The status of the shutdown switch does not change
Return the shutdown switch to the RUN position. states after returning the shutdown switch to the RUN
position.
C. Use the electronic service tool to observe the status of the shut-
down switch. Proceed to Test Step 3.
(continued)
480 M0070030-01
Circuit Tests
(Table 329, contd)

Short Circuit
3. Create a Short at the Connector for the Shutdown Switch Result: The status of the shutdown switch changed states
after creating the short circuit.
Repair: Install a new shutdown switch.
B. Disconnect the connector for the shutdown switch.
C. Create a short circuit at the connector for the shutdown switch
between terminal 1 and terminal 2. Result:The status of the shutdown switch did not change
states after creating the short circuit.
Repair: Repair the wiring or replace the harness.
E. Use the electronic service tool to observe the status of the shut-
down switch. Use the electronic service tool to verify that the problem is
resolved.
F. Remove the wire short.
Open Circuit
4. Create an Open at the Connector for the Shutdown Switch Detected Result: The status of the shutdown switch changed states
after creating the open circuit.
Repair: Install a new shutdown switch.
B. Disconnect the connector for the shutdown switch.
Use the electronic service tool to verify that the problem is
C. Turn the keyswitch to the ON position. resolved.
D. Use the electronic service tool to observe the status of the shut- Result: The status of the shutdown switch did not change
down switch. states after creating the open circuit.
Repair: Repair the harness or replace the harness.
Use the electronic service tool to verify that the problem is

resolved.
i06920226
Solenoid Valve - Test
Use this procedure to troubleshoot a problem with a

solenoid valve. Also, use this procedure if one of the
following diagnostic codes is active or easily
repeated.
Table 330
J1939 Code PDL Code (code descriptions may vary)
677-5 444-5 Engine Starter Motor Relay : Current Below This code indicates that there is a problem
Normal with the engine starter motor relay and/or the
electrical circuit on the ECM.
677-6 444-6 Engine Starter Motor Relay : Current Above This code indicates that there is a problem
Normal with the engine starter motor relay and/or the
electrical circuit on the ECM.
(continued)
M0070030-01 481
Circuit Tests
(Table 330, contd)

1074-5 2232-5 Engine (Exhaust) Brake Output : Current Be- This code indicates that there is a problem
low Normal with the engine retarder solenoid and/or elec-
trical circuit on the ECM.
1074-6 2232-6 Engine (Exhaust) Brake Output : Current This code indicates that there is a problem
Above Normal with the engine retarder solenoid and/or elec-
trical circuit on the ECM.
2791-5 3405-5 EGR Valve Control : Current Below Normal This code indicates that there is an electrical
problem with the solenoid valve and/or circuit
on the NRS valve actuator
2791-6 3405-6 EGR Valve Control : Current Above Normal This code indicates that there is an electrical
problem with the solenoid valve and/or circuit
on the NRS valve actuator.
2949-5 1922-5 Engine Intake Valve Actuation System Oil This code indicates that there is a problem
Pressure Control Valve : Current Below with the Engine Intake Valve Actuation Sys-
Normal tem Oil Pressure Control Valve circuit or
solenoid.
2949-6 1922-6 Engine Intake Valve Actuation System Oil This code indicates that there is a problem
Pressure Control Valve : Current Above with the Engine Intake Valve Actuation Sys-
Normal tem Oil Pressure Control Valve circuit or
solenoid.
3361-5 3821-5 Aftertreatment #1 DEF Dosing Unit : Current This code indicates that there is a problem
Below Normal with the DEF injector and/or the electrical cir-
cuit for the DEF injector. Refer to Test Step 4.
3361-6 3821-6 Aftertreatment #1 DEF Dosing Unit : Current This code indicates that there is a problem
Above Normal with the DEF injector and/or the electrical cir-
cuit for the DEF injector. Refer to Test Step 4.
3363-5 3126-5 Aftertreatment #1 DEF Tank Heater : Current This code indicates that there is a problem
Below Normal with the coolant diverter valve and/or the
electrical circuit for the coolant diverter valve.
3363-6 3126-6 Aftertreatment #1 DEF Tank Heater : Current This code indicates that there is a problem
Above Normal with the coolant diverter valve and/or the
electrical circuit for the coolant diverter valve.
3479-5 2461-5 Aftertreatment #1 Fuel Pressure Control : This code indicates that there is a problem
Current Below Normal with the pilot fuel solenoid and/or electrical
circuit on the CEM.
3479-6 2461-6 Aftertreatment #1 Fuel Pressure Control : This code indicates that there is a problem
Current Above Normal with the pilot fuel solenoid and/or electrical
circuit on the CEM.
4301-5 3182-5 Aftertreatment #1 Fuel Injector #1 Heater There is low current flow between the ECM
Control : Current Below Normal and the relay for the heating element.
The most likely cause of this code is an open
circuit in the wiring between the ECM and
the relay. There may be a problem with a
connector.
(continued)
482 M0070030-01
Circuit Tests
(Table 330, contd)

4301-6 3182-6 Aftertreatment #1 Fuel Injector #1 Heater There is excessive current flow between the
Control : Current Above Normal ECM and the relay for the heating element. If
the high current continues for 10 seconds,
the ECM disables the output for the heating
element. The power to the ECM must be
cycled to reset the fault detection circuit.
The most likely cause of this code is a short
circuit in the wiring between the ECM and
the relay. There may be a problem with a
connector.
5276-5 3409-5 Engine Exhaust Manifold Bank #1 Flow Bal- This code indicates that there is a problem
ance Valve Actuator Control : Current Below with the exhaust balance valve solenoid and/
Normal or electrical circuit.
5276-6 3409-6 Engine Exhaust Manifold Bank #1 Flow Bal- This code indicates that there is a problem
ance Valve Actuator Control : Current Above with the exhaust balance valve solenoid and/
Normal or electrical circuit.
5423-5 3427-5 Aftertreatment #1 Fuel Pump Relay Control : This code indicates that there is problem with
Current Below Normal the relay and/or circuit for the ARD electric
fuel pump.
5423-6 3427-6 Aftertreatment #1 Fuel Pump Relay Control : This code indicates that there is problem with
Current Above Normal the relay and/or circuit for the ARD electric
fuel pump.
5424-5 3413-5 Aftertreatment #1 Fuel Flow Diverter Valve This code indicates that there is a problem
Control : Current Below Normal with the solenoid on the diverter valve and/or
the electrical circuit on the ARD electric fuel
pump.
5424-6 3413-6 Aftertreatment #1 Fuel Flow Diverter Valve This code indicates that there is a problem
Control : Current Above Normal with the solenoid on the diverter valve and/or
the electrical circuit on the ARD electric fuel
pump.
5425-5 3391-5 Aftertreatment #1 Fuel Pressure #2 Actuator This code indicates that there is a problem
Control : Current Below Normal with the main fuel solenoid and/or electrical
circuit on the CEM.
5425-6 3391-6 Aftertreatment #1 Fuel Pressure #2 Actuator This code indicates that there is a problem
Control : Current Above Normal with the main fuel solenoid and/or electrical
circuit on the CEM.
5965-5 3838-5 Aftertreatment #1 DEF Control Module Relay This code indicates that there is a problem
Control : Current Below Normal with the PETU main power relay circuit or the
PETU main power relay.
5965-6 3838-6 Aftertreatment #1 DEF Control Module Relay This code indicates that there is a problem
Control : Current Above Normal with the PETU main power relay circuit or the
PETU main power relay.
M0070030-01 483
Circuit Tests
Table 331
Component Controller Electrical Checkout
DEF Coolant Diverter Valve Solenoid
Override: Turn the keyswitch to the OFF
position for 2 minutes. The keyswitch must
be off for 2 minutes to allow the DEF pump
to purge, to reset the code, and to reset the
Coolant Diverter Valve Diesel Exhaust Fluid Controller (DCU)
DCU.
Turn the keyswitch to the ON position.
Initiate the DEF Coolant Diverter Valve Sole-
noid Override through CAT ET to activate
the coolant diverter valve circuit.
DEF Dosing System Verification Test: Ini-
tiate the “DEF Dosing System Verification
DEF Injector Diesel Exhaust Fluid Controller (DCU)
Test” through Cat ET to activate the injector
circuit.
Start the engine. Use the “Intake Valve Ac-
tuation System Test” in diagnostic tests in
Cat ® Electronic Technician (ET) to activate
Engine Intake Valve Actuation System Oil Pres-
A4:E4 Engine ECM the “Engine Intake Valve Actuation System
sure Control Valve
Oil Pressure Control Valve” . Once the test
is complete, review the active diagnostic co-
des to determine the code that is present.
Engine Retarder Solenoid Override: Ini-

tiate an “Engine Retarder Solenoid Over-
Engine Retarder Solenoid A4:E4 Engine ECM ride” through Cat ET to activate the engine
retarder solenoid. Review active diagnostic
codes to determine what code is present.
Use the “Engine Exhaust Manifold Bank 1

Flow Balance Valve Solenoid Override” in
the override parameters section in Cat ET to
Exhaust Balance Valve Solenoid A4:E4 Engine ECM
activate the exhaust balance valve solenoid.
Review active diagnostic codes to deter-
mine what code is present.
Use the “ARD Fuel Flow Diverter Actuator

Override” in the override parameters section
in Cat ET to activate the fuel diverter valve
Fuel Diverter Valve A5:E2 Aftertreatment ECM
on the ARD fuel pump. Review active diag-
nostic codes to determine what code is
present.
ARD Ignition Test:Complete an ARD igni-

tion test through Cat ET as a final verification
of the repair. This circuit is continuously
Main Control Solenoid A5:E2 Aftertreatment ECM
monitored in T4F software and does not re-
quire performing the electrical checkout dur-
ing troubleshooting.
Turn the keyswitch to the OFF position for 2

minutes. The keyswitch must be off for 2 mi-
nutes to allow the DEF pump to purge, to re-
PETU Main Power Relay A5:E2 Aftertreatment ECM
set the code, and to reset the DCU.
Turn the keyswitch to the ON position.
Check for an active code.
(continued)
484 M0070030-01
Circuit Tests
(Table 331, contd)

Component Controller Electrical Checkout
ARD Ignition Test: Complete an ARD igni-
tion test through Cat ET as a final verification
of the repair. This circuit is continuously
Pilot Control Solenoid A5:E2 Aftertreatment ECM
monitored in T4F software and does not re-
quire performing the electrical checkout dur-
ing troubleshooting.
Use the “Aftertreatment Fuel Pump Relay

Override” in the override parameters section
Relay for ARD Fuel Pump A5:E2 Aftertreatment ECM in Cat ET to activate the ARD fuel pump.
Review active diagnostic codes to deter-
mine what code is present.
ARD Nozzle Heater Circuit Test: Initiate

the “ARD Nozzle Heater Circuit Test”
Relay for ARD Heater A5:E2 Aftertreatment ECM through Cat ET to activate the ARD heater
relay. Review active diagnostic codes to de-
termine if a code is present.
EGR System Test: Initiate the “EGR Sys-

tem Test” through Cat ET to activate the
control solenoid for the NRS valve. If the
Solenoid Valve for NRS Valve Actuator A4:E4 Engine ECM
fault becomes active, the test will abort. Re-
view active diagnostic codes to determine
what code is present.
Table 332
Required Tools
A T40-0241 Probe - Female 2

B T40-0240 Probe - Male 2
C T4000243 Break-out Connector 2
M0070030-01 485
Circuit Tests
486 M0070030-01
Circuit Tests
M0070030-01 487
Circuit Tests
Table 333
1. Determine the Diagnostic Code Diagnostic codes Result : There is an active or there is a logged 3361-5
(3821-5) or 3361-6 (3821-6) code.
and the applicable ECM. Refer to Troubleshooting, “Electronic Proceed to Test Step 4.
Service Tools”, if necessary.
Result : There is an active or there is a logged -5 code
other than a 3361-5 (3821-5) code.
B. Look for an active or logged -5 code or -6 code.
Result : There is an active or logged -6 code other than a

3361-6 (3821-6) code.
2. Check the Wiring for an Open Circuit Wiring Result : A -5 code became active during the electrical
checkout. There is an open circuit in the wiring between
A. Verify that the harness connector is free of debris, free of cor- the coil and the applicable ECM connector.
rosion, and securely connected.
Repair : Repair the connectors and/or the wiring.
B. Disconnect the solenoid from the applicable harness.
C. Connect a jumper wire between the terminals of the harness keyswitch must be off for 2 minutes to allow the DEF
connector for the suspect coil. The coil is replaced with a short pump to purge, the code to reset, and the DCU to reset.
circuit.
Verify that the original problem is resolved.
D. Perform the appropriate electrical checkout. Refer to Table
331 . Result : A -6 code is activated during the electrical check-
out. The applicable ECM detected the jumper wire. There
is a problem with the solenoid.
Repair : Replace the solenoid. Perform the electrical

checkout again to verify that the problem is resolved.
(continued)
488 M0070030-01
Circuit Tests
(Table 333, contd)

3. Check the Wiring for a Short Circuit Wiring Result : A -6 code became active during the electrical
checkout. The applicable ECM did not detect the open cir-
A. Disconnect the solenoid from the applicable harness. cuit. There is a short circuit in the wiring between the coil
and the applicable ECM connector.
B. Perform the appropriate electrical checkout. Refer to Table
331 . Repair : Repair the connectors and/or the wiring.

keyswitch must be off for 2 minutes to allow the DEF
pump to purge, the code to reset, and the DCU to reset.
Perform the electrical checkout again to verify that the

Result : A -5 code is activated during the electrical check-

out. The applicable ECM detected the open circuit. There
is a problem with the solenoid.
Repair : Replace the solenoid.

keyswitch must be off for 2 minutes to allow the DEF
pump to purge, the code to reset, and the DCU to reset.
Perform the electrical checkout again to verify that the

4. Measure the Resistance of the Injector Ohms Result : The resistance of the injector measured between
10 Ω to 14 Ω.
A. Turn the keyswitch to the OFF position. Allow 2 minutes to Proceed to Test Step 5.
Result : The resistance of the injector did not measure
B. Disconnect the DEF injector from the applicable harness. between 10 Ω to 14 Ω. A failed DEF injector has been
detected.
C. Inspect the connector for damage or debris.
Repair : Replace the injector. Refer to the Disassembly
D. Connect two of Tooling (A) to the DEF injector. The connectors and Assembly manual for the correct procedure.
must be used to prevent damage to the DEF injector connector.
Perform a DEF Dosing System Verification test using the
E. Measure the resistance of the DEF injector. The resistance electronic service tool to verify that the problem is
should be in the range of 10 Ω to 14 Ω. resolved.
(continued)
M0070030-01 489
Circuit Tests
(Table 333, contd)

5. Check for a Short Circuit in the Wiring Harness Ohms Result : The resistance of the DEF injector wiring harness
measured greater than 1k Ω.
A. Disconnect the injector from the harness.
B. Connect two of Tooling (B) to the DEF injector harness con-
nector. The connectors must be used to prevent damage to the Result : The resistance of the DEF injector wiring harness
DEF injector connector. measured less than 1k Ω. There is a short circuit in the
wiring harness between the DEF injector connector and
C. Measure the resistance between the DEF injector positive the DCU or there is an external short to ground.
wire and the DEF injector negative wire at the DEF injector
connector. Repair : Repair or replace the wiring harness.
D. Measure the resistance between the DEF injector positive Perform a DEF Dosing System Verification test using the
wire and a good ground. electronic service tool to verify that the problem is
resolved.
E. Measure the resistance between the DEF injector negative
wire and a good ground. The resistance should be greater than
1kΩ.
6. Check for an Open Circuit in the Wiring Harness Wiring Result: There is more than 10 Ω of resistance on any one
of the DEF injector circuit wires. There is an open in the
A. Disconnect the injector from the harness. harness.
B. Disconnect the PETU wiring harness from the DCU. Repair : Repair the wiring or replace the harness.
C. Connect two of Tooling (B) to the DEF injector harness con- Perform a DEF Dosing System Verification test using the
nector. The connectors must be used to prevent damage to the electronic service tool to verify that the problem is
DEF injector connector. resolved.
D. Connect one Tooling (C) to terminal 12 and one Tooling (C) to

terminal 32 on the 86-pin DCU connector. The Break-Out Con-
nectors must be used to prevent damage to the DCU
connectors.
E. Measure the resistance between terminal 1 on the DEF injec-

tor connector and terminal 32 on the 86-pin DCU connector.
F. Measure the resistance between terminal 2 on the DEF injec-

tor connector and terminal 12 on the 86-pin DCU connector.
i06692457 Note: Performing steps within this procedure

requires the use of a multimeter capable of
Speed Control - Test measuring a PWM duty cycle and frequency. Refer to
Table 334 for the tools recommended for the
procedure.
system if a problem is suspected with the circuit that
is for the throttle position sensor. Also use this
procedure if one of the diagnostic codes in Table 335
is active or easily repeated.
490 M0070030-01
Circuit Tests
Table 334
Recommended Tools
- Digital Multimeter
CVT0019 Adapter Cable As
Table 335
Code Description
The Electronic Control Module (ECM) has detected an invalid

combination of positions for the multi-position switches.
The code is logged. If equipped, the warning light will come
Accelerator Pedal Position #2 : Er-
29-2 774–2 on.
Engine RPM defaults to a predetermined safe speed. The
throttle switch is ignored by the ECM until the fault is cleared
and the keyswitch is cycled.

range.
Accelerator Pedal Position #2 : Volt-
29-3 774–3 The code is logged. The ECM flags the throttle position as in-
age Above Normal
valid data and a default value is used. The engine speed is
limited to high idle.

range.
29-4 774–4 The code is logged. The ECM flags the throttle position as in-
age Below Normal
The ECM detects an incorrect frequency on the throttle signal

Accelerator Pedal Position #2 : Ab- or an incorrect duty cycle on the throttle signal.
29-8 774–8 normal Frequency, Pulse Width, or The code is logged. The ECM flags the throttle position as in-
Period valid data and a default value is used. The engine speed is
The Electronic Control Module (ECM) has detected an invalid

combination of positions for the multi-position switches.
The code is logged. If equipped, the warning light will come
Accelerator Pedal Position #1 : Er-
91-2 91–2 on.
Engine RPM defaults to a predetermined safe speed. The
throttle switch is ignored by the ECM until the fault is cleared
and the keyswitch is cycled.

range.
91-3 91-3 The code is logged. The ECM flags the throttle position as in-
age Above Normal

range.
91-4 91-4 The code is logged. The ECM flags the throttle position as in-
age Below Normal
The ECM detects an incorrect frequency on the throttle signal

Accelerator Pedal Position #1 : Ab- or an incorrect duty cycle on the throttle signal.
91-8 91-8 normal Frequency, Pulse Width, or The code is logged. The ECM flags the throttle position as in-
Period valid data and a default value is used. The engine speed is
M0070030-01 491
Circuit Tests
The throttle position sensor is mounted to a pedal

assembly that allows the operator to control the
speed of the engine. The geometry of the pedal
assembly controls both the travel of the sensor and
the range of the output signal. The throttle position
sensor cannot be adjusted.
The output from the throttle position sensor is a PWM
signal that varies with the position of the throttle
pedal. The throttle position sensor produces a
minimum duty cycle in the released position and a
maximum duty cycle in the fully depressed position.
When the pedal is released, the ECM translates the
sensor output signal to a throttle position of 0
percent. When the pedal is fully depressed, the ECM
translates the output signal to a throttle position of
100 percent.
Table 336
1. Check the Signal Frequency and the Duty Cycle at the Frequency Result: The frequency and the duty cycle are within specifi-
Sensor cations for the entire range of the pedal.
Duty cycle
A. Turn the keyswitch to the OFF position. Repair: Repair the harness or replace the harness. Verify
B. Remove the wire from terminal location C (throttle position) on
the harness side of the connector for the throttle position sensor. Result: The ECM detects an incorrect frequency on the
throttle signal or an incorrect duty cycle on the throttle signal.
C. Install a CVT-0019 Adapter Cable As (3-PIN BREAKOUT) at The frequency is below 150 Hz or the frequency is above
the connector for the throttle position sensor. 1000 Hz. The duty cycle is less than 5 percent or the duty
cycle is greater than 95 percent.
D. Connect the connector for the throttle position sensor.
F. Measure the frequency and the duty cycle between terminal B

(digital return) and terminal C (throttle position) at the CVT-0019
Adapter Cable As (3-PIN BREAKOUT). Operate the throttle pedal
while making the measurements.
Turn the keyswitch to the OFF position.
Remove the breakout harness. Restore the wiring for the harness
connector to the original configuration.
2. Check the Supply Voltage to the Sensor 7.5 VDC Result: The supply voltage is above 7.5 VDC at the sensor
connector.
A. Turn the keyswitch to the OFF position. The wiring is OK.
B. Disconnect the harness connector for the throttle position Repair: Replace the sensor. Verify that the problem is
sensor. resolved.
C. Measure the voltage across terminal A (8 V supply) and termi- Result: The supply voltage is not above 7.5 VDC at the sen-
nal B (digital return) on the harness side of the connector. sor connector.
The supply voltage is not reaching the speed control.
Repair: Repair the harness wiring or replace the harness.

492 M0070030-01
Circuit Tests
i06692466
Speed/Timing - Test

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 337 is active or easily repeated.
Table 337
The code is logged. The Electronic Control Module (ECM) can

default to the secondary engine speed/timing sensor. The de-
Engine Speed Sensor : Abnormal Fre- fault will occur if a valid signal is not received from the primary
190-8 190-8
quency, Pulse Width, or Period 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.
The code is logged. If a valid signal is not received from the

secondary engine speed/timing sensor, the ECM will default to
Secondary Engine Speed Sensor : Abnormal the primary engine speed/timing sensor. The engine will shut
723-8 342-8
Frequency, Pulse Width, or Period down only if the signals from the primary engine speed/timing
sensor and the secondary engine speed/timing sensor are
abnormal.
The engine uses two engine speed/timing sensors. • The engine may require a slightly longer amount
Both sensors detect the reference for engine speed of time to start up.
and timing from a unique pattern on the camshaft
gear. The ECM uses the pattern of the pulses to • The engine may run rough for a few seconds until
determine the position of the crankshaft. The ECM the ECM determines the proper firing order by
measures the time between the pulses that are using the primary engine speed/timing sensor
created by the sensors as the gears rotate to only.
determine rpm.
The engine will start and the engine will run when
Under normal operation, the secondary engine only one sensor signal is present from either of the
speed/timing sensor is used to determine timing for sensors. Loosing the signal from both of the sensors
starting purposes. The secondary engine speed/ during engine operation will result in the termination
timing sensor is used to determine when the piston in of injection. The ECM will then shut down the engine.
the No. 1 cylinder is at the top of the compression The loss of the signal from both of the sensors during
stroke. The primary engine speed/timing sensor is start-up will prevent the engine from starting.
then used to determine engine speed and the signal
from the secondary camshaft sensor is ignored. Both sensors are magnetic sensors with an integral
connector. The two sensors are not interchangeable.
After locating the No. 1 cylinder, the ECM triggers Do not switch the positions of the sensor. If the
each injector in the correct firing order and at the sensors are replaced, a timing calibration is not
correct unit injector timing. The actual timing and necessary for the engine.
duration of each injection is based on engine rpm
and load. If the engine is running and the signal from
the primary engine speed/timing sensor is lost, a
slight change in engine performance will be noticed.
The change will be noticed when the ECM performs
the changeover to the secondary engine speed/
timing sensor. Loss of the signal from the secondary
engine speed/timing sensor during engine operation
will not result in any noticeable change in engine
performance. However, if the signal from the
secondary engine speed/timing sensor is not present
during start-up the following conditions may exist:
M0070030-01 493
Circuit Tests

Schematic for the engine speed/timing sensors

steps are listed.
Table 338
1. Check the Engine Speed/Timing Circuit Circuit Check Result: The engine started.
Result: The engine did not start.
C. Monitor the “Engine Starting” screen in the electronic service tool.
D. Start the engine and run the engine. The problem may occur
when the engine is at any operating temperature. However, the prob-
lem is more likely to occur when the engine is at the normal operat-
ing temperature.
2. Check for Diagnostic Codes Diagnostic Result: There is an active diagnostic code or there is a
Codes timing pattern that is “Not Detected” .
A. While the engine is running, monitor the electronic service tool for
diagnostic codes. Also monitor the “Engine Starting” screen for an Proceed to Test Step 5.
engine speed/timing that is “Not Detected” .
Result: There is not an active diagnostic code and there
B. Wait at least 30 seconds for activation of the diagnostic codes. is not a timing pattern that is “Not Detected” .
Look for these codes on the electronic service tool:
· 190-8 Repair: Troubleshoot any diagnostic codes that may be
· 342-8 present.
· 723-8 Return the unit to service.
(continued)
494 M0070030-01
Circuit Tests
(Table 338, contd)

3. 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 4.
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”.
4. 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.

Typical left side engine view
(1) Crankshaft speed/timing sensor

(2) Camshaft speed/timing sensor
M0070030-01 495
Circuit Tests
Table 339
5. Inspect the Sensor Assembly Sensor Result: The sensor and the sensor assembly mounting
Inspection are OK.
Do not reconnect the harness connector. Proceed to Test
B. Visually inspect the sensor and the sensor assembly without re- Step 6.
moving the sensor assembly from the engine. Flanges (2) must be
flush against the surface of the front timing gear housing (1) to en- Result: The sensor and/or the sensor assembly has a
sure proper operation. mechanical problem or the harness has debris and/or
corrosion.
C. Inspect bracket (3). Verify that the bracket securely holds the
flanges of the sensors flush against the engine. Repair: Repair the sensor and/or the sensor assembly or
replace the sensor and/or the sensor assembly.
D. Verify that the bracket is not bent. If the bracket is bent or if an ob-
struction is preventing the sensor assembly from being installed cor- Repair: Replace the sensor and the sensor harness con-
rectly, the engine will not start. nector if there was debris and/or corrosion.
E. Disconnect the harness from the speed/timing sensors. Check Verify that the problem is resolved.
the harness for debris and for corrosion.
F. Perform a 45 N (10 lb) pull test on the harness wiring.

Terminal locations at the connector for the speed/
timing sensors
(1) Engine speed/timing signal (−)
(2) Engine speed/timing signal (+)
496 M0070030-01
Circuit Tests
Table 340
6. Use a Multimeter to Check the Harness Wiring Check Wir- Result: The voltage was OK for all the measurements.
ing Harness
A. Turn the keyswitch to the ON position. The harness and wiring are OK. Proceed to Test Step
7.
B. Perform the following procedure for each sensor.
Result: The voltage was not OK for at least one of the
1. Measure the voltage between terminal 1 and a good engine ground. measurements.
The voltage is 2.4 ± 0.2 VDC.
There is a problem in the harness wiring.
2. Measure the voltage between terminal 2 and a good engine ground. Repair: Repair the appropriate harness wiring or re-
The voltage is 2.4 ± 0.2 VDC. place the appropriate harness.
7. Measure the Resistance of the Sensor Sensor Result: The resistance measurement for the sensor is
Resistance within the specification. There is no damage to the sen-
A. Turn the keyswitch to the OFF position. sor tip.
B. Disconnect the engine harness from the sensor. If the engine was running before removing the sensor,
reinstall the sensor.
C. Remove the sensor. Check the sensor tip for any damage. Use the electronic service tool to check for any active
diagnostic codes. Troubleshoot any active diagnostic
D. For the primary engine speed/timing sensor, measure the resistance codes.
between terminal 2 (Primary engine speed/timing +) to terminal 1 (Pri- Return the unit to service.
mary engine speed/timing −). If the engine was not running before removing the sen-
Resistance: 75 Ohms to 230 Ohms sor, refer to Troubleshooting, “Engine Cranks but Does
Not Start”.
E. For the secondary engine speed/timing sensor, measure the resist-
ance between terminal 2 (secondary engine speed/timing +) to terminal Result: The resistance measurement for the sensor is
1 (secondary engine speed/timing −). within the specification. There is damage to the sensor
Resistance: 600 Ohms to 1800 Ohms tip.
Inspect the housing for a cause of the sensor damage.

Make any necessary repairs.
Repair: Replace the sensor assembly.
Result: The resistance measurement for the sensor is

not within the specification.
Inspect the housing for a cause of the sensor damage.

Make any necessary repairs.
Repair: Replace the sensor assembly.
i06692474
Switch Circuits - Test
Use the following procedure to troubleshoot a

problem with a switch circuit. The procedure that
follows also covers the diagnostic codes that are
listed in Table 341 .
M0070030-01 497
Circuit Tests
Table 341
Diagnostic Codes
J1939 Code PDL Description Comments

This code indicates a fault in the circuit for the
air filter restriction switch.
Engine Air Filter 1 Differential Pressure : Volt- The air filter restriction circuit is open or
107-3 582-3
age Above Normal shorted for at least 1 second while the engine
is not running. The open or short circuit de-
pends on the configuration of the switch.
Tables 342 and 343 contains the normal engine

conditions and switch states for the air filter
restrictions switch.
Table 342
Normally Open Air Filter Restriction Switch
Engine Condition Switch State

Not running Open
Running Closed
Table 343
Normally Closed Air Filter Restriction Switch
Engine Condition Switch State

Not running Closed
Running Open
498 M0070030-01
Circuit Tests
Table 344
1. Check the “ Air Filter Restriction Switch Configura- Air Filter Restriction Switch Results : The switch is configured to “Normally
tion”” . Configuration Open” .
A. Turn the keyswitch to the ON position. Proceed to Test Step 2.
B. Connect to the electronic service tool. Results : The switch is configured to “Normally
Closed” .
C. Under “Configuration Parameters” check the “Air Filter
Restriction Switch Configuration” . Proceed to Test Step 3.
2. Check the Air Filter Restriction Switch Diagnostic codes Results : There is not an active 107-3 or 582-3 fault
code. A failed air filter restriction switch has been
A. Turn the keyswitch to OFF. detected.
B. Disconnect the air filter restriction switch from the wiring Repair : Replace the air filter restriction switch.
harness connector.
Verify that the repairs eliminated the issue. Return
C. Turn the keyswitch to ON. the machine to service.
D. Monitor the electronic service tool for active fault codes. Results : There is an active 107-3 or 582-3 fault
code. A short circuit in the wiring harness has been
detected.
Repair : Repair or replace the wiring harness.
Verify that the repairs eliminated the issue.
3. Check the Air Filter Restriction Switch Diagnostic codes Results : There is not an active 107-3 or 582-3 fault
code. A failed air filter restriction switch has been
A. Turn the keyswitch to OFF. detected.
B. Disconnect the air filter restriction switch from the wiring Repair : Replace the air filter restriction switch.
harness connector.
Verify that the repairs eliminated the issue. Return
C. Install a jumper wire in the wiring harness connector be- the machine to service.
tween the signal and ground wires.
Results : There is an active 107-3 or 582-3 fault
D. Turn the keyswitch to ON. code. An open circuit in the wiring harness has been
detected.
E. Monitor the electronic service tool for active fault codes.
Repair : Repair or replace the wiring harness.
Verify that the repairs eliminated the issue.
i06692484
Variable Valve Actuator - Test
Table 345 lists the diagnostic trouble codes that are

covered by this procedure. Also, use this procedure if
you have been directed from Troubleshooting,
“Symptom Troubleshooting”.
M0070030-01 499
Circuit Tests
Table 345
Diagnostic Trouble Codes for the Intake Valve Actuators
J1939 PDL
Code Code Description Information
2950-5 1901-5 Engine Intake Valve Actuator #1 : Current Below Normal The ECM monitors the current flow through the circuit
for each actuator. If low current flow (open circuit) is
2950-6 1901-6 Engine Intake Valve Actuator #1 : Current Above Normal detected, a -5 diagnostic code is activated. The ECM
continues to try to activate the actuator. If high current
2951-5 1902-5 Engine Intake Valve Actuator #2 : Current Below Normal
flow (short circuit) is detected, a -6 diagnostic trouble
2951-6 1902-6 Engine Intake Valve Actuator #2 : Current Above Normal code is activated. The ECM will disable the solenoid
circuit to prevent damage from the high current flow.
2952-5 1903-5 Engine Intake Valve Actuator #3 : Current Below Normal However, the ECM will periodically try to activate the
actuator. If the short circuit remains, this sequence of
2952-6 1903-6 Engine Intake Valve Actuator #3 : Current Above Normal events will be repeated until the problem is corrected.
The ECM takes the following actions while the code is
2953-6 1904-6 Engine Intake Valve Actuator #4 : Current Above Normal active:
2954-5 1905-5 Engine Intake Valve Actuator #5 : Current Below Normal Engine power is derated by 10 percent.
2954-6 1905-6 Engine Intake Valve Actuator #5 : Current Above Normal The amber warning lamp is illuminated.
These codes are usually caused by a wiring problem.
2955-6 1906-6 Engine Intake Valve Actuator #6 : Current Above Normal The wiring problem can be on the outside of the en-
gine or underneath the valve cover.
System Operation During Engine Operation

The intake valve actuation system does not operate
until the engine has reached normal operating
temperature. Also, the engine must meet certain
operating conditions to activate the intake valve
actuation system.
There are three housings under the valve cover.
Each housing contains two actuators. There is a
solenoid for each actuator. The ECM sends a
command to a solenoid when the ECM requires the
intake valves for a cylinder to remain open. The ECM
monitors the current flow through the circuit for the
solenoid. The ECM activates a diagnostic code if the
current flow is below normal or above normal.
“ Intake Valve Actuator Solenoid Test””
This test is available on the electronic service tool.
The test helps diagnose problems with the circuits for
the solenoids. The following conditions must be met
before the test will function:
• Engine speed must be zero.

• Vehicle speed must be zero.
• The transmission gearshift lever must be in
neutral.
500 M0070030-01
Circuit Tests

Schematic for the valve actuators
M0070030-01 501
Circuit Tests

P2 terminals for the intake valve actuators
(18) Actuator 4 return
(58) Actuator 5 & 6 supply
502 M0070030-01
Circuit Tests
Table 346
1. Inspect the Electrical Connectors and the Wiring Moisture Result: The wiring is OK.
A. Check the engine harness between the P2 connector and the Damage to If you are troubleshooting a -5 code, proceed to Test Step 2.
connectors near the grommets. Look for the following problems: connectors
If you are troubleshooting a -6 code, proceed to Test Step 4.
1. Moisture Result: The wiring is not OK.
2. Loose connectors or damaged connectors
3. Damage that is caused by excessive heat Repair: Repair the wiring problem. Replace parts, if neces-
4. Damage that is caused by chafing sary. Perform the “Intake Valve Actuator Solenoid Test” .
6. Damaged insulation If all the actuators pass the test, troubleshooting is com-
plete. Return the unit to service.
B. Inspect the connectors near the grommets. The connectors
must be clean and dry.
C. Perform a 45 N (10 lb) pull test on each of the wires in the con-
nectors. This test verifies that the wire is properly crimped to the
terminal and that the terminal is properly inserted into the
connector.
2. Short the External Wiring Harness Short Circuit Result: The test result indicated “Not Active: Device Open”
indicated for the suspect cylinder.
A. Connect a jumper wire to the engine harness connector. Con- The ECM did not detect the jumper wire. There is an open
nect the jumper wire between the appropriate terminals for the circuit in the wiring between the valve cover connector and
supply and for the return of the suspect actuator. the P2 connector. There may be a problem inside a
The jumper will replace the actuator and the valve cover wiring connector.
harness with a short circuit. Refer to Illustration 193 or Illustration
194 . Repair: Repair the wiring problem. Replace parts, if neces-
sary. Connect all the electrical connectors.
B. Perform the “Intake Valve Actuator Solenoid Test” . Determine Perform the “Intake Valve Actuator Solenoid Test” . Verify
the test result for the suspect cylinder. that all the cylinders pass the test.
Result: The test result indicated “Not Active: Device Short”

for the suspect cylinder.
The ECM detected the jumper wire. The external engine wir-
ing harness is OK.
3. Inspect Wiring Under the Valve Cover Damage to Result: The suspect cylinder passed the test. the problem is
wires or resolved.
A. Remove the valve cover. Look for these problems: connectors
Return the engine to service.
1. Loose connectors or damaged connectors
2. Damage that is caused by excessive heat Result: The suspect cylinder failed the test.
3. Damage that is caused by chafing Repair: Replace the appropriate actuator housing.
5. Damaged insulation Verify that all actuators pass the “Intake Valve Actuator Sole-
noid Test” after the new housing is installed.
Repair any wiring problems. Replace parts, if necessary.
Return the engine to service.
Connect all the electrical connectors.
Perform the “Intake Valve Actuator Solenoid Test” .
(continued)
M0070030-01 503
Circuit Tests
(Table 346, contd)

4. Create an Open in the External Wiring Harness Open Circuit Result: The test result indicated “Not Active: Device Short”
for the suspect cylinder.
A. Disconnect the appropriate connector near the grommets. This The ECM did not detect the open circuit. There is a short cir-
action will replace the actuator and the valve cover wiring harness cuit in the wiring between the valve cover connector and the
with an open circuit. P2 connector. There may be a problem inside a connector.
Repair: Repair the wiring. Replace parts, if necessary.
Refer to Illustration 193 or Illustration 194 . Connect all the electrical connectors and perform a “Intake
Valve Actuator Solenoid Test” . Verify that all the cylinders
B. Perform the “Intake Valve Actuator Solenoid Test” . Determine pass the test.
the test result for the suspect cylinder.
Result: The test result indicated “Not Active: Device Open”
for the suspect cylinder. The ECM detected the open circuit.
The external engine wiring harness is OK.
5. Inspect Wiring Under the Valve Cover Damage to Result: The suspect cylinder passes the test, the problem is
wires or resolved. STOP.
A. Remove the valve cover. Look for these problems: connectors
Result: The suspect cylinder failed the test.
1. Loose connectors or damaged connectors Repair: Replace the appropriate actuator housing. Verify
2. Damage that is caused by excessive heat that all actuators pass the “Intake Valve Actuator Solenoid
3. Damage that is caused by chafing Test” after the new housing is installed.
Repair any wiring problems. Replace parts, if necessary.
Connect all the electrical connectors.
Perform the “Intake Valve Actuator Solenoid Test” .
i06692562
Variable Valve Actuator

Response - Test
Use this procedure to diagnose mechanical problems

or electrical problems with the intake valve actuation
system. The following diagnostic codes indicate that
there is a mechanical problem or an electrical
problem with the system:
504 M0070030-01
Circuit Tests
(1) Control valve (3) Check valve

(2) Pressure sensor (4) Actuators
Table 347
Diagnostic Codes for Mechanical Problems or Electrical Problems with the Intake Valve Actuation System
J1939 PDL
Code Code Description Conditions Which Can Cause The Code
2949-7 1922-7 Intake Valve Actuation Oil Pressure not responding This code can only occur soon after the engine has started.
This code indicates that the difference in rail pressure is incorrect

while the control valve is opened and closed. The following condi-
tions can cause this code:
A control valve that contains debris or a control valve that is not

operating correctly
Damaged O-ring seal or missing O-ring seal.
2950-7 1901-7 Intake Valve Actuator 1 not responding The intake valve actuator is not responding correctly to the com-
mands from the ECM. This error can be caused by the following
2951-7 1902-7 Intake Valve Actuator 2 not responding conditions :
2952-7 1903-7 Intake Valve Actuator 3 not responding
There is an oil leak in the system.
There is a problem with an actuator.
The valve lash is incorrect.
The adjustment of an actuator is incorrect.
2948-7 E1101 (2) Engine Intake Valve Actuation System Oil Pressure The Engine Intake Valve Actuation System Oil Pressure did not
: Not Responding Properly change when the Engine Intake Valve Actuation System Oil Pres-
sure solenoid is toggled.
2948-17 E488 (2) Engine Intake Valve Actuation System Oil Pressure The Engine Intake Valve Actuation System Oil Pressure solenoid
: Low - moderate severity (2) is commanded closed, but the oil pressure does not go up.
Note: Resolve any electrical problems with the Symptoms

system before you use this procedure.
M0070030-01 505
Circuit Tests
The following symptoms may occur if there is a

problem with the intake valve actuation system.
• Intermittent check engine light

• Intermittent reductions in engine power
You may need to apply a load to the engine to verify
that the problem is resolved. The test must be
performed at 75 percent of the engine rated fuel rate
for at least 30 seconds.
Table 348
1. Check the Engine Oil Level Oil level Result : The engine oil level is OK.
A. Stop the engine. Allow the engine to cool approximately Repair : Record the engine oil level. Verify that the dipstick
20 minutes so the oil level can stabilize. is calibrated correctly. Refer to Operation and Maintenance
Manual, “Engine Oil Level Gauge - Calibrate”.
B. Check the engine oil level.
Result : The engine oil level is low.
Repair : Verify that the dipstick is calibrated correctly. Refer

to Operation and Maintenance Manual, “Engine Oil Level
Gauge - Calibrate”. Add engine oil to the proper level. Re-
cord the amount of engine oil that was added. Verify that
the repair resolved the problem.
If the problem has not been eliminated, proceed to Test

Step 2.
Result : The engine oil level is high.
Repair : Verify that the dipstick is calibrated correctly. Refer

to Operation and Maintenance Manual, “Engine Oil Level
Gauge - Calibrate”. Record the amount of engine oil that
was drained. Verify that the repair resolved the problem.
If the problem has not been eliminated, proceed to Test

Step 8.
Table 349
Oil Pressure Table
Engine Speed Pressure kpa Pressure psi
800 233 34
1400 326 47
1800 420 61
2100 503 73
506 M0070030-01
Circuit Tests

Oil pressure map
M0070030-01 507
Circuit Tests
Table 350
2. Check the Engine Oil Pressure Engine oil pressure Re- Result : The engine oil pressure is within
fer to Table 349 specifications.
and the engine ECM. The communication adapter must be Result : The engine oil pressure is low. Record the
communicating on both data links to perform this procedure. engine oil pressure. Record the engine rpm.
Refer to Troubleshooting, “Electronic Service Tools” for more in-
formation, if necessary. Repair : If there are any active diagnostic codes
that are related to low oil pressure, refer to the ap-
C. Install a mechanical gauge to the engine to read engine oil propriate topic in Troubleshooting, “Oil Pressure Is
pressure. Refer to Systems Operation, Testing and Adjusting, Low”.
“Engine Oil Pressure - Test”.
If the pressure is constant throughout the rpm
D. Turn the keyswitch OFF. range, there is a problem with the circuit for the en-
gine oil pressure sensor. Check the wire for the
pressure sensor supply terminal A for an open
circuit.
If there are no diagnostic codes that are related to

low oil pressure, refer to Systems Operation, Test-
ing and Adjusting, “Engine Oil Pressure - Test”.
3. Determine the Logged Code Diagnostic codes Result : A 1922-7 or 2949-7 code is active or
logged.
B. Turn the keyswitch ON.
Result : An E488 (2), E1101 (2), 2498-7, or 2948-
C. Check for active or logged diagnostic codes. 17 code is active or logged.
Result : A 2950-7 through 2955-7 or a 1901-7

through 1906-7 code is active or logged.
508 M0070030-01
Circuit Tests

Holes on the side of the control valve

Positions of the spool
When the valve is fully open, the spool blocks
approximately 40 percent of the hole.
(12) Spool
M0070030-01 509
Circuit Tests

Checking the position of the spool with a penlight
(12) Spool
(13) Penlight
(14) Valve body
Table 351
4. Check the Control Valve Control valve Result : The spool was not fully closed when the control
valve was removed from the engine.
Repair : Replace the control valve. Clear all logged
B. Disconnect the harness connector from the control valve. Care- codes.
fully remove the control valve from the engine.
C. Refer to Illustration 197 . Carefully wipe the oil from the holes
on the side of the control valve. Result : The spool was fully closed when the control
valve was removed from the engine.
D. Look for debris in the holes. Be sure to look at all the holes.
Note any debris that was found in the holes. If large amounts of Proceed to Test Step 5.
debris are found, determine the source of the debris before you
continue with this procedure.
E. Remove the debris if the debris can be easily removed. Other-

wise, replace the contaminated control valve with a new control
valve.
F. Look through a hole to determine the position of spool (12). The

spool should be closed. Use a penlight to determine the position of
the spool if necessary.
G. Shine penlight (13) into valve body (14) as shown in Illustration

199 . Press up the end of the penlight against the valve body to di-
rect as much light as possible into the valve body. Light shining be-
tween valve body (14) and spool (12) indicates that the spool is
not fully closed.
510 M0070030-01
Circuit Tests

Top view of the right rear of a typical 2806F engine.
Two O-ring seals are installed at location (26)
between quill tube (24) and jumper tube (25). One O-
ring seal is installed at face seal (27) between jumper
tube (25) and the valve cover base.
Illustration 200 g01329207 Locations (26) and (27) apply to each of the actuators.
Actuator on a 2806F engine (3) Check valve
(15) Leak points near the solenoids (24) Quill tube
(16) Purge orifices (25) Jumper tube
(26) Joint between the quill tube and the jumper tube
(27) Face seal between the jumper tube and the valve cover base

Right side view of the front of a typical 2806F engine.
An O-ring seal is installed at locations (20) and (21).
(20) Joint between the sensor and the valve cover base
(21) Joint between the control valve and the valve cover base
Illustration 201 g01313403 (26) Joint between the quill tube and the jumper tube
Right side view of the rear of a typical 2806F engine. (27) Face seal between the jumper tube and the valve cover base
Check valve (3) may be at the top of the oil supply

tube or at the bottom of the oil supply tube.
(3) Check valve
(23) Bottom of the tube for the oil supply to the rail
M0070030-01 511
Circuit Tests
Table 352
5. Perform a Leak Test Leak test Result : No leaks were detected.
Review the following information before you perform the Proceed to Test Step 6.
leak test.
Oil flow from some locations during this test is normal. Result : No leaks were detected and no oil flowed through
Leak Points Near the Solenoids - Clearances for moving hy- the purge orifice.
draulic components may cause slight oil leakage from locations
(15). Repair : Check the intake valve actuator system for debris
that could restrict the flow of oil.
Purge Orifice - purge orifice (16) allows air to purge from the
actuator. The purge orifice is on the bottom of some actuators. Proceed to Test Step 10.
Oil should stream from each purge orifice during this test.
Result : A leak was detected.
Oil should not flow from some locations. The following prob-
lems can cause oil to flow from these locations: Repair :Determine the source of the leak and repair the leak.
· Missing O-ring seal or damaged O-ring seal Clear all logged diagnostic codes.
· A component is loose.
· A component has an internal failure. Install the valve covers. Connect all electrical connectors.
The locations where oil should not flow on 2806F engines are Start the engine if a 2949-7 code was the only code that was
shown in Illustrations 201 , and 202 . logged. Run the engine for at least 30 seconds until the en-
gine coolant temperature is greater than 70 °C (158 °F). If a
A. Turn the keyswitch OFF. 2949-7 code does not return, the repair is complete.
B. Disconnect the connectors for the speed timing sensors. Proceed to Test Step 10.
Disconnection will prevent the engine from starting.
C. Disconnect the connector for the control valve. Disconnec-

tion will prevent the control valve from opening during the leak
test.
D. Remove the valve covers.
E. Wipe all the engine oil away from the following components:
· Face seals for the intake valve actuators
· Connection between the cylinder head and the valve cover
base
· Plugged ports on the intake valve actuators
· Plugged ports on the valve cover base
· The solenoids for the intake valve actuator
Do not crank the engine for more than 30 seconds.

Have a second person crank the engine while you check for
leaks if necessary.
F. Crank the engine.
G. Check for oil leaks around all the components under the
valve cover.
H. Verify that all the ports in the oil rail are plugged.
I. Verify that the oil flows through the purge orifice on the intake
valve actuator.
512 M0070030-01
Circuit Tests
Table 353
6. Check the Check Valve Check valve Result : The check valve is “OK” .
A. Remove the check valve. Proceed to Test Step 7.
B. Inspect the check valve. Look for debris that could cause Result : The check valve is damaged.
the check valve to stick.
Repair : Replace the check valve. Proceed to Test
Step 10.
An E488 (2), E1101 (2), 2498-7, 1922-7, 2949-7 or

2948-17 code is active or logged. proceed to Test
Step 7.
Result: A 2950-7 through 2955-7 or a 1901-7

through 1906-7 code is active or logged.

Typical example
(28) Sensor connector
(29) Intake valve actuation pressure sensor
(30) Fabricated tool
Table 354
Air Pressure Versus Signal Voltage
Air Pressure Range Low Typical Volt- Range High

(psi) (VDC) age (VDC) (VDC)
0 0.3 0.5 0.7
50 0.8 0.9 1.1
100 1.2 1.3 1.5
M0070030-01 513
Circuit Tests
Table 355
7. Test the Intake Valve Actuation Pressure Sensor Pressure Result : The voltage measurements are within range.
sensor
A. A pressure regulating assembly will be used to regulate air Proceed to Test Step 8.
pressure to the intake valve actuation pressure sensor. Refer
to Illustration 204 . In addition to the pressure regulating as- Result : The voltage measurements are not within the ac-
sembly, the technician will need a digital multimeter. ceptable range.
The fabricated tool consists of the following fittings and
components: Repair : Replace the intake valve actuation pressure sensor.
· 5/16 JIC Female to 1/4 JIC Male
· 1/4 JIC Female Swivel to 1/4 NPT Male Proceed to Test Step 10.
· 1/4 JIC Maleto 1/4 NPT Male
· Pressure regulator
B. Fabricate the above assembly.
C. Turn the keyswitch OFF.
D. Disconnect the connector for the intake valve actuation

pressure sensor.
E. Remove the intake valve actuation pressure sensor from

the valve cover base.
F. Install the fittings and the pressure regulator onto the intake
valve actuation pressure sensor.
G. Connect the connector for the intake valve actuation pres-

sure sensor to the engine harness.
Note : Ensure that the air pressure setting is less than 50 psi
before applying air pressure onto the test apparatus.
H. Apply shop air pressure to the assembly.
I. Turn the keyswitch ON.
J. Measure the voltage between terminals 2 and 3 at the sen-

sor connector.
K. Apply the air pressure that is indicated in Table 354 to the

intake valve actuation pressure sensor. Record the voltage
measurements at the different air pressures.
8. Perform the Automatic “ Cylinder Cutout Test”” Cylinder Cutout Result : All the cylinders indicated “OK” during the “Cylinder
Test Cutout Test” .
under the “Diagnostics” menu. Result : One or more cylinders failed the “Cylinder Cutout
Test” .
C. Select the “Automatic Cylinder Cutout Test” on the elec-
tronic service tool. Repair : Diagnose the problem and then repair the cylinders
that failed the “Cylinder Cutout Test” before continuing with
D. Start the test. this procedure. Clear all logged diagnostic codes. Verify that
the repair has eliminated the problem in the cylinder.
(continued)
514 M0070030-01
Circuit Tests
(Table 355, contd)

9. Set the Lash Settings for the Intake Valve actuator Lash settings Result : The lash is set to specification.
A. Turn the keyswitch OFF. Proceed to Test Step 10.
B. Allow the engine to cool. Result : The lash is not set to specifications.
C. Remove the valve cover or covers from the engine. Repair : Set the lash back to specifications. Refer to Systems
Operation, Testing and Adjusting for more information.
D. Check the lash settings for the intake valve actuators. Refer
to Systems Operation, Testing and Adjusting for the proper
procedure.
10. Perform the “ Intake Valve Actuator Test”” Intake Valve Ac- Result : All cylinders indicate “OK” .
tuator Test
A. Start the engine. Allow the engine to operate until the cool- Return the unit to service.
ant temperature is at least 70 °C (158 °F).
Result : One or more cylinders indicate “Not OK” .
B. Access the “Intake Valve Actuator Test” in the “Diagnostic
Tests” under the “Diagnostic” menu. Proceed to Test Step 11.
C. After you adhere to the warnings, start the automatic “In-

take Valve Actuator Test” .
The test will cycle two times. Once the test is complete, the en-
gine speed will increase to 2100 rpm for 15 seconds. An “OK”
or “Not OK” will be displayed once the test is complete.
11. Replace the Valve Actuator Unit Actuator unit Result: The test completed successfully.
A. Replace the suspect intake valve actuator. Return the unit to service.
B. Perform the “Intake Valve Actuator Test” Result: The test did not complete successfully. There are ad-
ditional codes.
Repair : Troubleshoot the additional codes. Refer to Trouble-

shooting for the correct procedure.
i06693222 When the ignition keyswitch is turned to the ON

position, the switch in the sensor will close for 5
Water in Fuel - Test seconds. If the ECM does not detect a signal from
the sensor during this period, a 3547-3 diagnostic
code will become active.
Water-in-Fuel Sensor Operation This procedure covers the following diagnostic code:
The Water-in-Fuel sensor is a normally open sensor.

During normal operation, no signal is 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 45 seconds, a 97-15 or
E232 (1) event code will become active. This event
code can also be caused by a short in the sensor
circuit.
Water-in-Fuel Sensor Self-Check
M0070030-01 515
Circuit Tests
Table 356
Diagnostic Trouble Code for the Water-in-Fuel Sensor
J1939 PDL Description Notes

Code Code
97-3 3547-3 Water in Fuel Indicator : Voltage An open circuit in the Water-In-Fuel sensor circuit has been detected.
Above Normal
516 M0070030-01
Circuit Tests
Table 357
1. Inspect the Water in Fuel Sensor Active Codes Result: A 97-15 or E232 (1) code is active.
A. Turn the keyswitch to the OFF position. A failed sensor has been detected.
B. Disconnect the sensor from the wiring harness connector. Repair: Replace the sensor, return the unit to service.
C. Use a jumper wire to create a short between terminal 1 Result: A 97-15 or E232 (1) code is not active.
(SIGNAL) and terminal 2 (RETURN).
Remove the jumper wire.
E. Establish communication between the electronic service
tool and the applicable Electronic Control Module (ECM). Re-
fer to Troubleshooting, “Electronic Service Tools”, if
necessary.
F. Look for an active 97-15 or E232 (1) code after 45 seconds.
2. Measure the Voltage at the Sensor Connector Voltage Result: The measured voltage is 8VDC/ ±1VDC.
A. Turn the keyswitch to the OFF position. There is an open in the signal wire. Refer to the ma-
chine-specific schematic to troubleshoot the signal wire.
B. Disconnect the sensor connector.
Repair: Repair or replace the wiring harness as
C. Turn the keyswitch to the ON position. necessary.
D. Measure the voltage between pin 2 (RETURN) and pin 3 Return the unit to service.
(SUPPLY) on the wiring harness connector for the WIF
sensor. Result: The measured voltage is not 8VDC/ ±1VDC.
E. Turn the keyswitch to the OFF position. Proceed to Test Step 3.
3. Measure the Battery Supply Voltage at the Sensor Voltage Result: The measured voltage is 8VDC/ ±1VDC.
Connector
There is an open in the return wire. Refer to the ma-
A. Turn the keyswitch to the ON position. chine-specific schematic to troubleshoot the return wire.
B. Measure the voltage between pin 3 (SUPPLY) and a known Repair: Repair or replace the wiring harness as
good ground source on the wiring harness connector for the necessary.
WIF sensor.
C. Turn the keyswitch to the OFF position.
Result: The measured voltage is not 8VDC/ ±1VDC.
There is an open in the supply wire. Refer to the ma-

chine-specific schematic to troubleshoot the supply
wire.
Repair: Repair or replace the wiring harness as

necessary.
M0070030-01 517
Service
Service Ether injection Override

This override is used to activate the ether injection
solenoid circuit to ensure that the circuit is working
properly. The ether canister must be removed during
i06693226 testing of the ether solenoid circuit.
Service Tool Features Engine Fan Bypass

This override is used to turn ON the engine fan. The
override can be used to test the engine fan operation.
Note: With the release of Tier 4 Final engines, extra The engine fan speed is entered as a percent of full
emissions control system components have been speed, this percent allows the user to operate the fan
added to the engine to reduce the NOx output. The at different speeds.
addition of these components requires three
Electronic Control Modules (ECMs) for the engine Overrides Parameters Listed in the
and aftertreatment systems to operate. The most
recent version of the electronic service tool must be Engine #1 Aftertreatment Controller
used when connecting to the Electronic Control Menu
Modules. When viewing the Diagnostic or Event
Codes screens, ensure that the “Include All ECM's”
box is checked. Aftertreatment #1 DEF Dosing Control
Module Key Switch Line
Override Parameters
This override resets the Diesel Exhaust Fluid Control
The override parameters screen has multiple Unit (DCU) without having to cycle key power to the
overrides. The parameters control various functions other ECM's. The reset ensures that the diesel
on the engine and CEM. These functions and exhaust fluid controller completes a purge cycle,
features allow the technician to troubleshoot different resets any active codes, and shuts down correctly.
engine systems.
This test turns off the keyswitch power from the A5:
Electronic service tool location E2 Aftertreatment controller to the DCU for
approximately 2 minutes. Once the DCU has
successfully powered down and reset, the keyswitch
1. Connect to the electronic service tool. power supply will be turned back on. The DCU will
2. Select the appropriate Electronic Control Module then be operational.
(ECM)
Aftertreatment #1 Fuel Injector Heater #1
3. Select the Diagnostics tab.
Override
4. Select the Diagnostic Tests tab.
This override activates the output for the heated
5. Select the Override Parameter tab. nozzle to clean the nozzle. The output remains
activated for approximately 1 hour. The engine
Override Parameters Listed in the Engine coolant temperature must be greater than 60° C
(140° F). The heat cycle will wait for active
ECM Menu regeneration to complete before starting. Once the
override has been activated, the heat cycle will
Engine Exhaust Manifold Bank #1 Flow automatically start when conditions have been met
and cannot be deactivated. It could take up to 8
Balance Valve Solenoid Override minutes for conditions to be met for the heat cycle to
turn on after being activated by the override. The
The engine ECM will energize the exhaust balance heat cycle stops if the engine is stopped. The heat
valve solenoid to on or off. This override will be used cycle continues when the engine is started. Active
when troubleshooting the exhaust balance valve. regenerations will not occur until the heat cycle is
complete. This override will be used if a system
Fuel Priming Command Override malfunction was not allowing current to flow to ARD
nozzle heater. Lack of current flow could be caused
This override is used to verify that the ARD fuel by a blown fuse, broken heater wire, and other
diverter valve is working properly. The override damaged components.
activates the fuel priming pump. The diverter valve
blocks the supply to the ARD head and allows fuel to
flow into the engine fuel system.
518 M0070030-01
Service
Aftertreatment Fuel Pump Relay Override 3. Select the Diagnostic Tests tab.
The Engine #1 Aftertreatment Controller will allow the 4. Select “System Troubleshooting Settings” .
ARD fuel pump to provide fuel to the CEM. This
override will be used when pressure testing the ARD System Troubleshooting Settings Listed
fuel pump.
in the Engine ECM Menu
ARD Air Pressure Control Position
Engine Emissions Operator Inducement
Override
Service Mode Override
The ECM sends a command to the ARD air valve to
open to a specified percentage. The override is used The override is used by service technicians to stop
to check the operation of the valve while the inducement counter and disable engine
disassembled. restrictions due to inducement to troubleshoot. Once
the override is activated, navigation of other
electronic service tool functions is possible.
ARD Fuel Flow Diverter Actuator
Override This override allows the service technician to disable
the inducement to troubleshoot problems. Factory
This override is used to cycle the position of the passwords are required to perform this override as
diverter valve on the ARD fuel pump. The diverter the engine will be operating outside of the emissions
valve changes the path of the fuel between the window.
engine and the CEM.
Injector Disable Override
DPF Differential Pressure Line Override
This override will allow the user to disable the
This override when Activated, will ignore any fault injectors from activating when performing certain
code from the DPF Delta P sensor. This override will troubleshooting procedures.
be used when using the DPF crack detection
procedure. System Troubleshooting Settings Listed
in the Engine #1 Aftertreatment
Overrides Parameters Listed in the
Controller Menu
Diesel Exhaust Fluid Controller #1 Menu
DEF Coolant Diverter Valve Solenoid
Primary Override
Override
This override will energize the ARD ignition system to
The override is used to check the solenoid and
diverter valve harness electrically. This override will on or off. This override will be used when
troubleshooting the ARD ignition system.
open the coolant diverter valve which allows coolant
to flow through the PETU assembly. This test can be
used to verify that the coolant diverter valve is ARD Regeneration Override
working properly.
This override will allow the user to perform a DPF
DEF Dosing Injector Override regeneration that is similar to the operator using the
force switch.
This override allows the user to test the electrical Note: This override does not have any enhanced
circuit for the DEF injector. The override commands
the DEF injector to open. This override only operates diagnostic ability. All regeneration system
when there is no engine speed. troubleshooting should utilize the service tests and
not this override.
System Troubleshooting Settings
The “System Troubleshooting Settings” screen will
Active Diagnostic Codes
allow overrides to be enabled. The purpose of this screen is to show all the active
diagnostic codes.
Electronic service tool location
1. Connect to the electronic service tool and select
the appropriate ECM. 1. Connect to the electronic service tool.
M0070030-01 519
Service
2. Select the appropriate Electronic Control Module Troubleshoot Symptom

(ECM)
This tab is not available for Tier 4 engines. Refer to
3. Select the Diagnostics tab. the Troubleshooting guide.
4. Select the Active Diagnostic Codes tab.
Active Event Codes
Tab Functions At Bottom of Screen The purpose of this screen is to show all the active
event codes.
Reset Electronic service tool location

This tab will clear specific codes when highlighted.
Reset All 2. Select the appropriate Electronic Control Module
(ECM)
This tab will reset all the active codes.
Troubleshoot Code 4. Select the Events tab.
This tab is not available for Tier 4 engines. Refer to 5. Select the Active Events tab.
the Troubleshooting guide.
Tab Function At Bottom of Screen
Troubleshoot Symptom
This tab is not available for Tier 4 engines. Refer to Reset
Logged Diagnostic Codes
Reset All
The purpose of this screen is to show all the logged
diagnostic codes. This tab will reset all the active codes. Some of the
event codes will “latch” to active status. Repairing the
Electronic service tool location system will not “unlatch” the event codes and the
event codes must be reset with the electronic service
tool.
2. Select the appropriate Electronic Control Module Logged Event Codes
(ECM) The purpose of this screen is to show all the logged
event codes.
4. Select the Logged Diagnostic Codes tab. Electronic service tool location
Tab Functions At Bottom of Screen 1. Connect to the electronic service tool.

2. Select the appropriate Electronic Control Module
Clear (ECM)
This tab will clear specific codes when highlighted. 3. Select the Diagnostics tab.
4. Select the Events tab.
Clear All
5. Select the Logged Events tab.
This tab will clear all logged diagnostic codes.
Tab Functions At Bottom of Screen
Troubleshoot Code
This tab is not available for Tier 4 engines. Refer to Clear
Clear All
This tab will clear all logged diagnostic codes.
520 M0070030-01
Service
Troubleshoot Code This test requires that the engine is OFF and the key
switch is in the ON position (or ECM energized and 0
This tab is not available for Tier 4 engines. Refer to engine speed). If the engine is started with the wiggle
the Troubleshooting guide. test active, the wiggle test will abort.
Troubleshoot Symptom The Wiggle Test will reduce all ECM requirements to
trip fault codes, making the diagnostics sensitive.
Under normal operation some fault codes need
This tab is not available for Tier 4 engines. Refer to multiple occurrences before the code will log. But
the Troubleshooting guide. during this test the fault codes will trip the first time.
Diagnostic Tests The mechanic wiggles and shakes the wiring to see if
Electronic service tool diagnostic tests are listed codes go active. An audible alarm is also activated if
below. the ECM sees any parameter change state
electrically. Once the test has ended, the ECM
returns to normal diagnostic state.
Fuel Rail Pump Solenoid Test
1. Connect to the electronic service tool and select
the appropriate ECM. The high-pressure fuel pump contains two
assemblies for pressurizing fuel. Each assembly
contains a solenoid. This test checks each solenoid
3. Select the Diagnostic Tests tab. to make sure that the solenoids are working properly.
During the Fuel Rail Pump Solenoid Test, the ECM
Diagnostic Tests Listed in the Engine pulses 105-volt to each solenoid. The pulses are sent
ECM Menu at the proper time and for the correct duration for a
given engine load and speed. The ECM monitors the
current flow through the circuit for each solenoid. If
Injector Solenoid Test the current flow is too high or too low, the ECM
activates one of the following diagnostic codes:
The purpose of the injector solenoid test is to
diagnose injector wiring and injector solenoid • 1779-5 Fuel Rail Pump #1 Output Current Below
functionality. Normal
This test identifies an open circuit or a short circuit in • 1779-6 Fuel Rail Pump #1 Output Current Above
the circuit for the injector solenoids. The test Normal
activates the injector solenoids one at a time while
the engine is not running. A good solenoid will create • 1780-5 Fuel Rail Pump #2 Output Current Below
an audible click when the solenoid is activated. The Normal
electronic service tool indicates the status of the
solenoid as “OK” , “Open” , or “Short” . • 1780-6 Fuel Rail Pump #2 Output Current Above
Normal
Cylinder Cutout Test
Fuel System Verification Test
The cylinder cutout test allows one cylinder or
multiple cylinders to be cut out. The cylinder cutout The Fuel System Verification Test compensates for
test is useful when troubleshooting poor engine wear of the internal components of each injector over
performance or a suspected injector failure a time. Internal component wear contributes to lower
volumes of fuel being delivered into the cylinder.
The cylinder cutout test disables the injector by not Injector wear also increases the amount of leakage
providing the injector pulse to the solenoid. The past each injector back to the fuel tank. This test
cylinder cutout test can be performed on one injector evaluates the health of each injector.
or multiple injectors at once.
The engine ECM determines whether the injector is
Wiggle Test delivering the correct volume of fuel into the cylinder.
Also the engine ECM determines if the injector is
The purpose of the Wiggle Test is to detect delivering a low volume of fuel into the cylinder based
intermittent electrical faults in electronic control on Valve Closing Time. Valve Closing Time is the
systems. The Wiggle Test function allows the user to difference between the time the engine ECM stops
determine if there is an intermittent wiring problem. sending current to the injector solenoid and when the
The test will indicate (by changing the value reading) valve returns to the valve seat. When the test is
which parameter moved beyond a predetermined performed, the electronic service tool indicates the
range while wiggling the wiring harness, sensor, or status of each injector as “Success” or “Failed” .
connector.
M0070030-01 521
Service
Note: Perform the Fuel System Verification Test after • EGR Valve Response Test: Known conditions are
an injector is replaced. Also perform when a -2 or -7 established for the engine. The EGR valve is
code is active. commanded from open to closed. The response is
checked for the EGR Delta Pressure Sensor, EGR
Fuel System Functional Test Absolute Pressure Sensor, and fuel quantity. Each
input has a unique response time, which will be
The Fuel System Functional Test contains four compared to a threshold. The commanded EGR
separate tests that evaluate various aspects of the valve positions are held for a fixed amount of time
common rail fuel system. The test is a self-guided to allow the inputs to stabilize. This procedure is
test that will advance to the next test in the series if repeated several times to increase accuracy and
the current test passes. If a test in series fails, the repeatability.
test will abort.
• EGR Valve Sweep Test: Known conditions will be
• The Fuel Pump Gear Installation Test evaluates if established for the engine. The EGR valve is
the high-pressure fuel pump was installed swept from open to closed repeatedly to check for
correctly. satisfactory response of the EGR flow.
• The Low Rail Pressure Fuel Pump Flow Test
checks for leaks at low rail pressure. The test Diagnostic Tests Listed in the Engine #1
momentarily cuts out pumping and injection and Aftertreatment Controller Menu
measures the resulting rail pressure drop. The test
then calculates the fuel quantity leaving the rail
and compares to the expected results. Aftertreatment NOx Sensor Functional
Test
• The Fuel Rail High Pressure Test checks for fuel
leaks at high rail pressure. The test momentarily This test checks that the NOx sensors are working
cuts out pumping and injection and measures the properly.
resulting rail pressure drop. The test then
calculates the fuel quantity leaving the rail and The engine runs without the EGR to produce an
compares to the expected results. expected level of NOx. The SCR dosing is disabled
and the readings from the “Engine Out” and “Tailpipe
• The High Rail Pressure Fuel Pump Flow Test Out” NOx sensors are compared. The NOx levels are
assesses adequate fuel pump flow. The test expected to be similar.
measures rail pressure response during a single
pump event while fuel injection is disabled. Aftertreatment System Functional Test
Possible Test Results The test will check the entire DPF regeneration
system and the SCR dosing system.
• Fuel Pump Not Timed Correctly
The test will perform a short DPF regeneration similar
• Fuel Pump Flow Too Low to the ARD ignition test. The engine will operate
under conditions similar to a DPF Regeneration, but
• Fuel Rail High Pressure Decay Too High the SCR system is tested during this time. The test
will last approximately 15 minutes, then the test will
• Fuel Rail Low Pressure Decay Too High either complete successfully, or log a fault code for
the suspect component.
EGR System Test
ARD Air System Service Test
Method to determine the EGR System health and
determine if the EGR system is functioning properly. The ARD air system service test is to determine if the
The test will exercise the EGR valve, and check for ARD air valve is controlling airflow as commanded by
exhaust gas flow. the controller. This test will determine if the ARD air
valve is functioning properly.
The test is conducted with the engine running at a
constant speed and load with machine/vehicle speed The ARD air valve is cycled while the ECM monitors
zero. boost and aftertreatment secondary air pressure. The
There are two phases to the test: ECM looks for a specific amount of drop in boost and
aftertreatment secondary air pressure when the valve
is actuated. The values must be higher than the
threshold to pass the test.
522 M0070030-01
Service
ARD Fuel Line Purge Test DEF Dosing Control Module Reset
This diagnostic test is used to initiate an ARD fuel This function resets the Diesel Exhaust Fluid Control
system air purge sequence to remove any air trapped Unit (DCU) without having to cycle key power to the
in the system after assembly or repair/service in the other ECM. The reset ensures that the diesel exhaust
field that can introduce air into the system. fluid controller completes a purge cycle, resets any
active codes, and shuts down correctly.
The test allows a quantity of fuel to flow through the
ARD fuel supply lines by enabling the electric This test turns off the keyswitch power from the A5:
priming/ARD fuel pump, and activating the pilot and E2 Aftertreatment controller to the DCU for
main fuel valves until that there is consistent and approximately 2 minutes. Once the DCU has
adequate fuel pressure on the main and pilot fuel successfully powered down and reset, the keyswitch
control pressure signals. power supply will be turned back on. The DCU will
then be operational.
ARD Ignition Test
Diagnostic Tests Listed in the Diesel
The ARD ignition test is used when completing Exhaust Fluid Controller #1 Menu
maintenance to the ARD system, or for diagnosing a
failed ignition event, or for loss of combustion.
DEF Dosing System Purge Test
The technician can initiate an ARD Ignition Test
below 80 percent soot level. The test is a shortened This test verifies that the DEF purging process is
DPF regeneration (approx. 4 minutes). The test working correctly by purging the DEF pump and
checks all the components of ARD system. The ARD lines.
ignition test checks the functionality of the system to
verify that ignition has occurred and combustion is This service test is used to purge the DEF system.
maintained. The ARD Ignition test also actuates the This test turns on the DEF pump and opens the
Main Fuel Solenoid (If Equipped). reverting valve. The opening of the reverting valve
will cause the DEF to be pumped from the injector
back into the tank. This draining allows the user to
ARD Nozzle Heater Circuit Test de-pressurize the system prior to working on the
system.
The ARD Nozzle Heater Circuit Test allows the
technician to verify that the heated nozzle and nozzle
circuit are functioning properly. DEF Dosing System Accuracy Test
The test cycles the ARD fuel nozzle heater on for 3 This test is used with the T400236 DEF Test Kit to
minutes, or until the test is aborted by the technician. measure the amount of DEF that the SCR dosing
The 3 minutes will give the technician time to perform system is spraying into the exhaust system. The test
an electrical check on the heater. Perform the can also be used to verify visually that there is an
electrical test by hooking an ammeter around the acceptable spray pattern from the DEF Injector.
heater wire to verify that the heater is getting the
proper current. Engine speed must be present while Note: The DEF injector must be removed from the
this test is running to allow coolant to circulate exhaust system during this test and placed in an
through the ARD head. Once the current has been appropriate container. Failure to do so could result in
measured, the test can be aborted. issues with the SCR system operation. Refer to
Testing and Adjusting, “Aftertreatment SCR System
Aftertreatment Diesel Exhaust Fluid Tank Dosing Test”
Heater Test This test turns on the DEF pump and opens the DEF
injector. The DEF injector atomizes the DEF and the
This test opens the coolant diverter valve, allowing spray pattern must be uniform in order for the SCR
coolant to flow through the DEF tank and DEF pump. system to work properly. Once the test is completed,
The software monitors the increase in DEF the DEF pump will purge the system. The user must
temperature to ensure that the coolant diverter valve check to see if the amount of DEF in the container
is working correctly. meets the specification.
This test requires the engine to be running. The DEF
tank temperature is monitored throughout the test. DEF Heated Lines Test
When the test is started, the engine operates with the
coolant diverter valve closed for a period. Then the This test checks the electrical circuit integrity by
coolant diverter valve is opened for a period. The A5: activating the line heaters. The test is used to
E2 aftertreatment controller compares the validate a repair made to any of the heated line
temperature difference and determines whether the circuits.
coolant diverter valve is functioning properly.
M0070030-01 523
Service
This test turns on all the line heaters. The test will
cycle the line heaters on and off for 5 minutes. After 5
minutes, the test will turn off. This test is used to
check the line heater circuit for faults.
DEF Dosing System Verification Test

This test primes the dosing system. The test is used
to ensure that the DEF pump is able to build
adequate pressure.
This test turns on the DEF pump for 5 minutes.
During this time, the DEF pump will pressurize the
entire DEF dosing system to operating pressure. The
DEF injector will open momentarily to purge air out of
the line. Then the DEF injector will close again to
maintain a constant pressure within the dosing Illustration 205 g02157706
system. The DEF pump will purge the system at the
end of the test. Illustration 206 indicates that the trim files have been
applied. The trim files correct the injectors back to
nominal so the injectors all inject the same amount at
Calibrations the same time.
The electronic service tool calibrations are listed
below.

(ECM)
4. Select the Calibrations tab.
Calibrations Listed in the Engine ECM

Menu Illustration 206 g02157717
Injector Trim Calibration Note: If the injectors fall outside of the main window,
the injectors are scrapped.
Injector trim files calibrate each injector. The injectors
are calibrated so the injectors will deliver a precise Air Inlet Temperature Sensor Installation
amount of fuel at the exact time needed.
Calibration
Each injector is tested to verify the accuracy of the
injector duration and timing. If the injectors do not 1. Select Air Inlet Temperature Sensor Installation
pass, the injectors are not used. If the injectors do Calibration and click Start.
pass, trim files are created and the injectors are
installed. The trim file adjusts the duration and timing 2. Click Next and then click Accept.
of each injector, so the injectors all function the
same. When new injectors are installed, the
technician records the serial numbers of each injector
and searches for the injectors in Perkins Technical
Marketing Information (PTMI). The trim files can be
downloaded and stored on a pc. The technician loads
the trim file for each injector into the ECM.
Illustration 205 indicates each injector that falls in the
box is a good injector that passed the tests.
524 M0070030-01
Service
3. Click Yes and the engine should be placed under a

relatively high load and high engine speed
operating condition. This load does not
necessarily have to be the highest possible load
the installation could see. If loading the engine is
not possible, increase the engine speed to 1800
RPM.
4. Enter the ambient temperature from thermocouple
or hand held thermometer, then click OK. The
ambient temperature must be below the Air Inlet
Temperature displayed in the window. Measure
the ambient temperature in the shade away from
hot air flow generated from the fan. Make sure to
use Celsius if the electronic service tool is set up in
Celsius.
5. The engine should be placed under a relatively
high load and high engine speed for 2 minutes
then click Next. If loading the engine is not
possible, increase the engine speed to 1800 RPM
for 2 minutes then click Next.
M0070030-01 525
Service
6. Click Yes and decrease the engine speed to low

idle (600 - 700 RPM) and remove any load from
the engine.
526 M0070030-01
Service
7. Enter the ambient temperature from thermocouple

or hand held thermometer, then click OK. The
ambient temperature must be below the Air Inlet
Temperature displayed in the window. Measure
the ambient temperature in the shade away from
hot air flow generated from the fan. Make sure to
use Celsius if the electronic service tool is set up in
Celsius.
8. Run the engine at low idle (600 - 700 RPM) and
remove any load from the engine for 2 minutes
and then click Next.
M0070030-01 527
Service
9. The calibration value has been calibrated. Write

down the calibration so you can enter the
calibration value in the configuration parameters.
Next, click Accept.
528 M0070030-01
Service
10. Calibration Successful, ignore “Conditions Not Dyno Mode

Met” displayed in above window for Engine Intake
Manifold Mass Flow Rate. Go to Configuration, Dyno Mode is used to run an engine on a dyno
select “System Settings” , and enter the calibrated without derates or diagnostic trouble codes tripping
from missing machine components. Normally, while
value into the Air Inlet Temperature Sensor in chassis an ECM is looking for inputs from various
Calibration. Factory Passwords are required to machine components, like the transmission ECM or
program this value. body ECM. Dyno Mode does not require the CEM to
be installed. If the ECM does not see the inputs, the
Dyno Mode ECM assumes that something is wrong and sets a
diagnostic trouble code.
Electronic service tool location 1. Select the Dyno Mode tab.
1. Connect to the electronic service tool. 2. Select “Enable” to enable dyno mode.
2. Select the appropriate Electronic Control Module 3. Return to the Service tab.
(ECM) 4. Select the Service Procedures tab.
4. Select the Dyno Mode tab.
M0070030-01 529
Service
5. Select the power train Protection Reset (Available

on certain models).
530 M0070030-01
Service
6. Select “Reset Protection” .

The engine is installed on the dyno and the
technician selects Dyno mode. Dyno mode tells the
engine ECM that the engine is on a dyno and the
ECM ignores all the normal inputs from the machine.
Once in dyno mode, if the engine has multiple power
ratings the highest rating should be selected.
M0070030-01 531
Service
532 M0070030-01
Service
Service Procedures Service Procedures Listed in the Engine

The electronic service tool service procedures are #1 Aftertreatment Controller
listed below.
Ash Service Regeneration
This regeneration is used to clean 100 percent of the
1. Connect to the electronic service tool. soot out of the DPF prior to cleaning the diesel
particulate filter.
(ECM) This regeneration has a fixed length of time that the
regeneration heats up the DPF and burns out soot
3. Select the Service tab. that has built up during operation. This service
4. Select the Service Procedures tab. procedure is done before an ash servicing has taken
place, and the regeneration makes the ash cleaning
more effective.
Service Procedures Listed in the Engine
ECM Menu Manual DPF Regeneration
None Manual Regenerations are used by the technician to
regenerate the DPF and troubleshoot the
aftertreatment system.
M0070030-01 533
Service
This type of regeneration lasts a minimum of 10

minutes, and can be performed even if soot loading is
at 0 percent. If a problem is encountered during the
regeneration, the diagnostics are tuned to alert the
technician. This regeneration also tests the ARD
nozzle for plugging by comparing desired and actual
DPF inlet temperature.
DPF Ash Service

The engine ash model must be reset whenever the
filter is cleaned or replaced. Resetting the ash model
places the DPF volume back to the “Clean State” .
The resetting will allow the regeneration of the DPF
to function properly.
1. Highlight “DPF Ash Service” . Select “Start” .
534 M0070030-01
Service
M0070030-01 535
Service
2. Select “Ash Service Reset” to start the test

procedure.
536 M0070030-01
Service
3. Choose the correct replacement type of diesel

particulate filter in the menu that appears. The
types of replacements for the diesel particulate
filter are the following:
• “Field cleaned” A filter that has been cleaned

and reapplied
• “New” - A new filter replacement
• “Remanufactured” - A remanufactured filter

replacement
M0070030-01 537
Service
538 M0070030-01
Service
4. Once the reset is completed, a log of the reset is

captured. The log is visible as a new row of
information in the DPF ash service screen.
Resetting the engine ash model does not reset the
soot level.
5. Perform a “Manual DPF Regeneration” with the
electronic service tool to reset the soot level.
Diesel Oxidation Catalyst (DOC) Reset

The Diesel Oxidation Catalyst Replacement
procedure must be performed when the DOC has
been replaced. This procedure is necessary to
ensure that the engine meets emissions
requirements. Follow the procedure below to reset
the DOC model in the aftertreatment software.
M0070030-01 539
Service
1. Select “Diesel Oxidation Catalyst Replacement”

and select “Start” .
540 M0070030-01
Service
2. Select “Reset” .
M0070030-01 541
Service
542 M0070030-01
Service
3. Read the warning and select “Accept” to continue.
M0070030-01 543
Service
4. Once the reset is completed, a log of the reset is

captured. The log is visible as a new row of
information in the Diesel Oxidation Catalyst
Replacement screen.
Aftertreatment SCR Catalyst

Replacement
The Aftertreatment SCR Catalyst Replacement
procedure must be performed when the SCR
Catalyst has been replaced. This procedure is
necessary to ensure that the engine meets emissions
requirements. Follow the procedure below to reset
the SCR Catalyst model in the aftertreatment
software.
544 M0070030-01
Service
2. Connect to “Engine #1 Aftertreatment Controller” .
M0070030-01 545
Service
3. Select “Service” from the top menu and select

“Service Procedures” .
546 M0070030-01
Service
4. Select “Aftertreatment #1 SCR Catalyst

Replacement” and select “Start” .
M0070030-01 547
Service
5. Select “Reset” .
548 M0070030-01
Service
6. Read the warning and select “Accept” to continue.

7. Enter the factory passwords to continue.
M0070030-01 549
Service
8. Once the reset is completed, a log of the reset is 2. Select the Engine #1 Aftertreatment Controller.
captured and visible as a new row of information in
3. Select the Information tab.
the “Aftertreatment #1 SCR Catalyst
Replacement” screen.
“ Aftertreatment Abnormal Shutdown
ARD Fuel Line Flush History””
The ARD Fuel Line Flush enables the service This feature allows the user to see when the engine
technician to flush potential debris from the ARD fuel was shut down improperly. This screen shows hot
lines. The flushing helps to prevent the ARD nozzle shutdown events, and cold shutdown events.
from becoming plugged after being serviced.
A hot shutdown can damage the aftertreatment or
The ARD Fuel Line Flush allows a quantity of fuel to SCR system.
flow through the ARD supply lines. The flush is
accomplished by enabling the ARD fuel pump, and A cold shutdown can damage the SCR dosing
activating the pilot and main solenoid valves. The system.
ECM cycles the pilot and main solenoids on for 10
seconds and off for 10 seconds. The ECM repeats Aftertreatment Regeneration History
the cycles four times. The pilot and main lines MUST
be disconnected from the ARD head and allowed to Regeneration history provides details on how recent
flow fuel into a container. The container must be able regenerations have been triggered and shutdown.
to hold 5 gal of fuel for this procedure.
Regeneration history should only be used for
Note: DO NOT ATTEMPT TO RUN THIS TEST troubleshooting with diagnostic and event codes.
WITH THE FUEL LINES STILL CONNECTED. The Never troubleshoot the system off regeneration
history alone.
DPF could be damaged.
Aftertreatment History
550 M0070030-01
Service
(1) Aftertreatment Regeneration Speed (6) Application Regeneration Readiness (10) Regeneration End Time
Type Status (11) Regeneration Completion Service
(2) Aftertreatment Regeneration Trigger (7) Aftertreatment Regeneration Trigger Hours
Type Percent Soot (12) Aftertreatment Regeneration End
(3) ARD Auto Regeneration Enable Status (8) Aftertreatment Regeneration End Speed Percent Soot
(4) Regeneration Start Time Type (13) Aftertreatment Regeneration End
(5) Regeneration Trigger Service Hours (9) Aftertreatment Regeneration End Trigger Status
Type
Column Headings Enabled – All regeneration types are allowed

Automatic Low Speed Regeneration Only –
1. (Column 1) Aftertreatment Regeneration Speed
Stationary or forced regenerations are the only
Type regeneration types allowed
The regeneration was low speed (stationary) or Disabled – Regeneration is disabled through the
high speed (working). electronic service tool.
2. (Column 2) Aftertreatment Regeneration Trigger
Type 4. (Column 4) Regeneration Start Time
What triggered the regeneration. Displays the date and time the regeneration
occurred.
Start-up – Triggered at engine start-up
5. (Column 5) Regeneration Trigger Service Hours
ARD Maintenance – Triggered to maintain ARD
system Machine hour meter reading at the start of the
regeneration.
SCR Maintenance – Triggered to maintain ARD
system 6. (Column 6) Application Regeneration
Readiness Status
Soot – Triggered by the ECM soot calculation
Status values 1 through 3 are indicative of high-
Pressure – Triggered by the DPF differential speed regeneration. Status values 4 and above
pressure sensor
are indicative of a low speed regeneration.
Service – Triggered through the electronic service
7. (Column 7) Aftertreatment Regeneration Trigger
tool
Percent Soot
3. (Column 3) ARD Auto Regeneration Enable The percent of soot when the regeneration was
Status triggered.
What the ECM configuration file was programmed 8. (Column 8) Aftertreatment Regeneration End
to at the time of the regeneration. Speed Type
M0070030-01 551
Service
The regeneration was low speed (stationary) or

high speed (working).
9. (Column 9) Aftertreatment Regeneration End
Trigger Type
What triggered the regeneration.
10. (Column 10) Regeneration End Time
The date and time the regeneration completed.
11. (Column 11) Regeneration Completion Service
Hours
The machine hour reading when the regeneration
stopped. The regeneration could stop when the
regeneration was successfully completed or when
the regeneration was stopped by the operator.
Percent Soot
The percent of soot when the regeneration
completed.
Status
What stopped the regeneration.
Unsuccessful – The regeneration did not complete
or stop normally
Complete – Regen completed
Work – Machine went back to work
Off – Machine was turned off
Disabled – Operator disabled the regeneration
Electronic Service Tool Snapshots

Snapshots allow viewing of data in the electronic
service tool approximately 9.5 seconds before and
3.5 seconds after the diagnostic trouble code was
recorded.
1. Select the “Information” tab. Select the “Snapshot”
tab, then select the “Viewer” tab.
552 M0070030-01
Service
2. Select the diagnostic trouble code to be viewed.

Select “View Data” .
M0070030-01 553
Service
3. Select a group or select “Temporary Group”
554 M0070030-01
Service
4. Select the channels to view and add the channels

to the group. Select “OK” .
M0070030-01 555
Service
5. The sliding time bar indicates when the diagnostic

trouble code was recorded. Data can be viewed
9.5 seconds before and 3.5 after the time the code
was recorded .
556 M0070030-01
Service
6. Select the “View Graph” tab for graphic

illustrations. Select the channels you want to view,
and select “OK” .
M0070030-01 557
Service
Histogram Screens
Tab Functions At Bottom of Screen
Histograms
This tab pulls up the histogram menu.
Clear
This tab is not available for Tier 4 engines.
Clear All
This tab will clear the current histogram data for this
key cycle.
Show All Labels

This function labels all bars in the graph.
View Labels on Mouseover

This function labels each bar in the graph as the
mouse pointer is moved over the bar.
558 M0070030-01
Service
Screen Shots
M0070030-01 559
Service
The amount of engine hours operated at indicated inlet temperature.

The amount of engine hours operated at indicated coolant temperature.
560 M0070030-01
Service

The amount of engine hours operated at indicated engine speed.

The amount of engine hours operated at indicated intake manifold air temperature.
M0070030-01 561
Service

The amount of engine hours operated at indicated intake manifold pressure.
562 M0070030-01
Service

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.
M0070030-01 563
Service

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.
564 M0070030-01
Service

This histogram is populated when the engine system has calculated a condition in which high exhaust
temperatures are present. A fault code will not be logged when the system calculates a high exhaust temperature
condition. But the high exhaust temperature will derate the engine to protect the engine system. This action is
normal under most circumstances and no additional troubleshooting is necessary. Refer to Troubleshooting,
“Exhaust Temperature is High” for additional information.
M0070030-01 565
Service

There are certain engine conditions that put the engine in danger of turbocharger overspeed. The engines are
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 turbocharger overspeed. In other words, the turbocharger has to work
harder to maintain the desired boost pressure. This action is normal under most circumstances and no additional
troubleshooting is necessary.
i06693946
Service Tool Error Identifiers
Service Error ID's are displayed when the electronic

service tool Service test has failed. The Service Error
ID's are to help explain why the service has test
failed. There could be cases when the service test
error ID will isolate the failed component. If applicable
use the appropriate troubleshooting procedure.
Table 358
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.
(continued)
566 M0070030-01
Service
(Table 358, contd)

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
like CANape, CANcases, and Supercom2.
$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 throttle switch, the switch
maybe faulty.
$101B Shift Lever Not in Neutral Shift Lever to Neutral
$101C Transmission Gear Incorrect Shift power train to Neutral
$1018 Parking Brake Not Engaged Apply parking brake
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 are actively in operation. Hydraul-
ics are not locked out. Implement lockout sol-
enoid is on Hoist and is not in float. AWD is
$1180 Machine is Not Idle installed and the AWD system is in Creep
mode (MG). Steering lockout is off. OK to ele-
vate speed switch is OFF (for Industrial appli-
cations only).
The machine is moving, stop the machine to

$1126 Ground Speed Too High
perform service test.
$1012 Lever Not in Correct Position Shift level to neutral.
$110C Brake Pedal Depressed Release the brake.
The DPF intake temperature is too high to

$112B Particulate Filter Intake Temperature Too High perform the test and system damage may
occur.
The temperature of the DPF is too low. Oper-
$112C Particulate Filter Intake Temperature Too Low ate the engine to raise the DPF Temperature.
Check for exhaust leaks.
Wait for a DPF regeneration to complete or
$115C Regeneration is Active
abort the test.
The DPF Soot Load must be reduced before
performing the test. Perform a Manual DPF
$1155 DPF Soot Loading Too High
Regeneration using the electronic service
tool.
The ARD Fuel Line Purge Test was not able
to purge air out of the fuel lines in the speci-
fied amount of time. Repeat the ARD Fuel
$1117 Fuel Pressure Too Low
Line Purge Test one time only. If unsuccessful,
refer to Troubleshooting, “ARD Fuel Pressure
Is Low”.
(continued)
M0070030-01 567
Service
(Table 358, contd)

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 temperature failed to rise as ex-

pected during the time allowed. There may be
Diesel Exhaust Fluid Tank Temperature Rise a problem with the DEF Coolant Diverter
$11BF
Too Low Valve or the coolant supply to the DEF tank.
Refer to Troubleshooting, DEF Temperature
Is Low for the correct procedure.
ARD Ignition Test
Resolve active diagnostics. Refer to appropri-

$0002 Active Diagnostic Present
ate story.
Engine must be running or engine speed has

$10FB Engine RPM Too Low
reduced during test.
Refer toTroubleshooting, “ARD Failed To

$1130 Aftertreatment Failed To Ignite
Ignite”.
EGR System Test
Resolve active diagnostics. Refer to appropri-

ate story
Refer toTroubleshooting, “NOx Reduction

Exhaust Gas Recirculation Mass Flow Rate
$1159 System - Test”. Refer to test step “Perform
Incorrect
EGR System Test” .

$1158 Delivered Fuel Volume Not Responding System - Test”. Refer to test step “Perform

Exhaust Gas Recirculation Intake Pressure
Not Responding

Exhaust Gas Recirculation Differential Pres-
sure Not Responding
Engine must be running, or Engine speed has

reduced during test.
Reduce engine speed before running service

$10FC Engine RPM Too High
test
ARD Air System Test
Aftertreatment #1 Secondary Air Pressure Not There is an air leak or restriction between the
$115D
Responding turbo compressor and the CRS System
There is an air leak or restriction between the

$115E Intake Manifold Pressure Not Responding
turbo compressor and Intake manifold

Engine must be running, or Engine speed has
reduced during test
$10FC Engine RPM Too High
ARD Nozzle Heater Circuit Test
(continued)
568 M0070030-01
Service
(Table 358, contd)

Check ARD head part number for your appli-
$1050 Battery Voltage Too High cation. There are specific parts for specific
system voltages.
$1010 Engine Stopped (No Engine RPM) Start the engine
$10A7 Coolant Temperature Too Low Allow the engine to warmup.
$115C Regeneration is Active Allow the regeneration to complete
$0006 Service Test Aborted by Tool/Monitor Abort by user, restart the test
Fuel System Functional Test
$111D Fuel Rail High Pressure Decay Too High
$111E Fuel Rail Low Pressure Decay Too High Refer to Troubleshooting, “Fuel Rail Pressure
is Low”. Refer to Test Step “Perform Fuel Sys-
$111F Fuel Pump Flow Too Low tem Functional Test” .
$1120 Fuel Pump Timing Incorrect
Do not allow engine RPM to fluctuate more

$1108 Excessive Engine RPM Change
than 100 RPM during test.
Coolant temperature must be greater than

$108C Coolant Temp Low
40° C (104° F)
Resolve any active diagnostic codes. Refer to

the appropriate troubleshooting procedure.
Fuel rate is too high for the test. Reduce load

$10CB Engine Load Too High
applied to the engine during the test.
Fuel System Verification Test

Engine must be running during the test, start

$10D0 Engine Has Not Been Running Long Enough
the engine before starting the test.
$10EF Machine Speed Not Zero Do not move the machine during the test.

Injector Fuel Delivery Test

Engine must be running during the test, start

$10D0 Engine Has Not Been Running Long Enough
the engine before starting the test.
Coolant temperature must be greater than

$108C Coolant Temp Low
65° C (149° F)
$10EF Machine Speed Not Zero Do not move the machine during the test.

Check the service tool connection, do not

$0009 Service Test Aborted by ECM abort the test before the test is complete. Re-
peat the test, if necessary.
ARD Fuel Flush Test
(continued)
M0070030-01 569
Service
(Table 358, contd)

The test cannot run with the engine running,

$1011 Engine Running (Engine RPM Present)
turn the engine OFF.
$1151 ARD Fuel Pressure #1 Too High Troubleshoot code E1050.
$1151 ARD Fuel Pressure #2 Too High Troubleshoot code E1051.
$0006 Service Test Aborted by Tool/Monitor Abort by user, restart the test.
Aftertreatment System Functional Test

$10FC Engine Speed Too High Lower the engine speed to idle.
Not all conditions were met in order for the

$105F Test Timed Out test to complete. Restart the Aftertreatment
System Functional Test.
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”.
There is too much NH3 in the exhaust. Per-
$11A9 Aftertreatment Outlet NH3 Too High form an ARD ignition test to raise the exhaust
temperatures.
Aftertreatment SCR Catalyst Reagent Temper- The temperature of the DEF is too low. Oper-
$11AA
ature Too Low ate the engine to raise the DEF Temperature.
The NOx sensors have not reached the cor-

Aftertreatment #1 NOx Level Sensors Not rect temperature to start reading the NOx Lev-
$11B5
Ready el. Perform an ARD ignition test to raise the
exhaust temperatures.
The SCR system cannot dose due to the en-

Aftertreatment SCR System Not Ready To gine operating temperatures not being high
$11BA
Dose enough. Restart the Aftertreatment System
Functional Test.
The temperature of the exhaust system is not
high enough to perform the test. Operate the
$11C2 Aftertreatment SCR System In Warm-up Mode engine to raise the exhaust temperatures. Re-
start the Aftertreatment System Functional
Test.
The SCR Dosing system cannot prime. Refer
$11C3 Aftertreatment SCR System Not Able to Prime
to Troubleshooting, “DEF Pressure is Low”.
The engine speed or load is above a thresh-

$1164 Engine Speed/Load Incorrect old, remove the load from the engine or re-
duce the engine speed to idle.
NOx Sensor Functional Test

$10FC Engine Speed Too High Lower the engine speed to idle.
(continued)
570 M0070030-01
Service
(Table 358, contd)

There was a change in the engine load while
the test was running. Make sure that the en-
$10F5 Excessive Change in Engine Load
gine load is constant while performing the
test.
The EGR Mass Flow Rate does not meet the
requirements for running the test. Refer to
$1159 EGR Mass Flow Rate Incorrect
Troubleshooting, “NOx Reduction System –
Test”.
The NOx sensors have not reached the cor-
Aftertreatment #1 NOx Level Sensors Not rect temperature to start reading the NOx Lev-
$11B5
Ready el. Perform an ARD ignition test to raise the
exhaust temperatures.
The Intake NOx Level Sensor is not respond-

ing to the engine operating conditions as ex-
$11B6 Intake NOx Level Sensor Not Responding
pected. Refer to Troubleshooting, “NOx
Sensor – Test”.
The Outlet NOx Level Sensor is not respond-
ing to the engine operating conditions as ex-
$11B7 Outlet NOx Level Sensor Not Responding
pected. Refer to Troubleshooting, “NOx
Sensor – Test”.
The NOx Level Sensors are not responding to
the engine operating conditions as expected.
$11B8 NOx Level Sensor(s) Not Responding
Refer to Troubleshooting, “NOx Sensor –
Test”.
The temperature of the exhaust system is not
high enough to perform the test. Operate the
$11C2 Aftertreatment SCR System In Warm-up Mode engine to raise the exhaust temperatures. Re-
start the Aftertreatment System Functional
Test.
The SCR Dosing system cannot prime. Refer
$11C3 Aftertreatment SCR System Not Able to Prime
to Troubleshooting, “DEF Pressure is Low”.
The engine speed or load is above a thresh-

$1164 Engine Speed/Load Incorrect old, remove the load from the engine or re-
duce the engine speed to idle.
Coolant Diverter Valve Test

$0006 Aborted by User The user has aborted the test.
The ECM lost communication with the service

$0009 Test Aborted by ECM
tool.
The DCU did not respond to the request to
$105F Test Timed Out start the test. Perform the “DEF Dosing Con-
trol Module Reset” . Repeat the test.
The engine coolant temperature is too low to

$10A7 Coolant Temperature Too Low start the test. Allow the engine to reach oper-
ating temperature prior to performing the test.
The DPF intake temperature is too high to

$112B Particulate Filter Intake Temperature Too High perform the test and system damage may
occur.
(continued)
M0070030-01 571
Service
(Table 358, contd)

The DEF tank level is too low to perform the
$11BB Diesel Exhaust Fluid Level Too Low
test. Add DEF to the tank.
The temperature of the DEF is too high to per-
$11BC DEF Temperature Too High
form the test.
The ambient temperature is too high to per-
$11BD Ambient Air Temperature Too High
form the test.
i06273960 • Program a new Electronic Control Module (ECM).

When an ECM is replaced, the system
Customer Passwords configuration parameters must be programmed
into the new ECM. A new ECM will allow these
parameters to be programmed once without
factory passwords. After the initial programming,
Customer passwords may be used to protect some parameters are protected by factory
customer parameters from being changed. The passwords.
electronic service tool can be used to change certain
parameters. There are some parameters that cannot • Clear event codes. Most event codes require the
be changed and there are some applications that do use of factory passwords to clear the code once
not allow any changes to the programmable the code has been logged. Clear these codes only
monitoring system. The passwords are programmed
into the Electronic Control Module (ECM) with the when you are certain that the problem has been
electronic service tool. One password may be corrected.
programmed or both passwords may be
programmed. If customer passwords are not • Unlock parameters. Factory passwords are
programmed, customer parameters may be changed required in order to unlock certain system
by anyone. configuration parameters. Refer to
Troubleshooting, “Configuration Parameters”.
To obtain customer passwords, contact the owner of
the engine. If the owner has forgotten the customer Since factory passwords contain alphabetic
passwords, factory passwords are used to create characters, the electronic service tool must be used
temporary customer passwords. Temporary to perform these functions. In order to obtain factory
customer passwords can be used to change the passwords, proceed as if you already have the
original customer passwords or any parameter that is password. If factory passwords are needed, the
protected by a customer password. When the electronic service tool will request the factory
electronic service tool is disconnected, you will be passwords. The electronic service tool will display the
prompted to restore the original customer passwords. information that is required to obtain the passwords.
If the original passwords are not restored, the
passwords will be changed to the temporary i06274006
passwords.
ECM Will Not Accept Factory
i05969825
Passwords
Factory Passwords
Probable Causes
NOTICE • Incorrect information for the password request
Operating the engine with a flash file not designed for
that engine will damage the engine. Be sure the flash • Incorrect passwords
file is correct for your engine.
Note: Factory passwords are provided only to

Perkins distributors.
Factory passwords are required to perform each of
the following functions:
572 M0070030-01
Service
Recommended Actions The following conditions can cause a communication

problem:
Check the Information for the Password • Incorrect communication adapter
Request
• Use of a parallel cable between the
The information for the password request must be communication adapter and the PC
obtained from the Engine Control Module (ECM) that
is being programmed. Do not use information from an • Incorrect version of electronic service tool
old ECM in order to program factory passwords on a
replacement ECM. • Incorrect firmware in the communication adapter
Verify that the information used to request that the • Incorrect configuration of the electronic service
password is identical to the information that is tool
displayed on the electronic service tool.
• A problem with electrical power to the
Engine Serial Number – The engine serial number communication adapter
must be from the electronic service tool screen rather
than the engine information plate. • A problem with electrical power to the engine ECM
Reason Code – Use the reason code from the • A problem with the wiring for a data link
factory password screen. Reason codes are
assigned for specific purposes and reason codes are • A problem with the electrical cables between the
not interchangeable. PC and the vehicle
Turn the key to the OFF position. Then, turn the

keyswitch to the ON position. Try to enter the
passwords again.
Incorrect Passwords
Verify that the correct passwords were entered.
Check each character in each password.
If rechecking the passwords does not correct the
problem, change a customer parameter. Change the
parameter from the current value to another value
and then change the customer parameter back to the
original value. The sequence of events will change
the total tattletale. The new total tattletale will require
obtaining new factory passwords. Obtain new factory
passwords and enter the passwords.
i06275670
Electronic Service Tool Does

Not Communicate
Use this procedure to solve communication problems

between the electronic service tool and the engine
control module (ECM). The electronic service tool
must communicate with the ECM on the J1939 data
link in order to service the engine.
Indicators on the communication adapter indicate
that communication is occurring on a particular data
link. The “J1939 / DeviceNet” indicator indicates that
the communication adapter is communicating on the
J1939 data link. The electronic service tool displays a
message during the connection if electronic service
tool cannot communicate on both data links.
M0070030-01 573
Service
Table 359
1. Determine the Problem Communication Result: Both indicators on the communication adapter
problem are not flashing.
A. Determine the communication problem.
If an indicator other than the “POWER” indicator is illuminated Proceed to Test Step 2.
when electronic service tool is not communicating with an
ECM, disconnect and reconnect the communication adapter. Result: The electronic service tool indicates that the en-
gine is serviced on the J1939 data link.
Result: The electronic service tool displays a message

that indicates the firmware in the communication adapt-
er does not support communication on the data link.
Result: The electronic service tool displays an Error “

#142 The interface hardware is not responding”
message.
Result: The electronic service tool displays a message

that indicates that the electronic service tool cannot find
an exact match for the software version in the ECM.
Repair: Update the electronic service tool to the latest

available version.
Result: The power indicator is not illuminated.
2. Verify that the Correct Communication Adapter is Being Communication Result: An incorrect communication adapter is being
Used adapter used.
A. A 27610401 Communication Adapter Gp must be used to Repair: Connect a correct communication adapter. Re-
communicate. fer to Troubleshooting, “Electronic Service Tools”, if
necessary.
B. Determine the communication adapter that is being used.
Attempt to establish communication. Continue with this
procedure if the communication adapter does not com-
municate on the data link.
Result: A correct communication adapter is being used.

However, the “Power” indicator is not illuminated.
Result: A correct communication adapter is being used.

The “Power” indicator is illuminated.
(continued)
574 M0070030-01
Service
(Table 359, contd)

3. Check the Version of the Firmware for the Communica- Firmware Result: The electronic service tool communicates on
tion Adapter both data links.
The version of the firmware for the communication adapter The problem is resolved.
must be the latest available.
Result: The electronic service tool does not communi-
A. Electronically disconnect the electronic service tool. Verify cate on both data links.
that the “power” indicator on the communication adapter is
illuminated. Proceed to Test Step 4.
B. Click on the “Utilities” menu.
C. Click on the “Comm Adapter III Toolkit” menu.
D. Wait for the tool kit to open. Then, click the “Utilities” menu.
E. Click “Application Firmware Flash” .
F. Select the latest “.apf” file from the list.
G. Click “OK” . Then, click “Begin Flash” .
H. Wait for the “Flashes Completed Successfully” message to

appear.
I. Attempt to connect the electronic service tool.
4. Verify that the Electronic Service Tool is Configured Configured correctly Result: The electronic service tool communicates on
Correctly the data link.
The electronic service tool must be configured correctly in order The problem is resolved.
to communicate on both data links.
A. Click on the “Utilities” menu. cate on both data links. The “POWER” indicator is not
illuminated.
B. Click on the “Preferences” menu.
C. Select the “Communications” tab.
D. Verify that “Communication Adapter III (Serial IP)” is cate on both data links. The “POWER” indicator is
selected. illuminated.
If “Communication Adapter III (Serial IP)” is not an option for se- Proceed to Test Step 6.
lection, the version of the electronic service tool is incorrect.
Update the version of the electronic service tool. Then, perform

this Test Step again.
E. Verify that the port is correct.
F. Verify that the “Enable Dual Data Link Service” option is

checked.
G. Click “OK” . The electronic service tool must reconnect in or-

der for any changes to be used.
(continued)
M0070030-01 575
Service
(Table 359, contd)

H. Electronically disconnect the electronic service tool if
changes are made to any of the settings for communications.
Electronically connect the electronic service tool. Attempt to es-
tablish communication. Observe the indicators on the commu-
nication adapter.
A “limited support” warning should not be displayed. The

“J1939 / DeviceNet” indicator should be flashing. The indicator
indicates that the electronic service tool is communicating on
both data links.

Power terminals at the service tool connector
(Terminal A) +Battery
(Terminal B) −Battery
576 M0070030-01
Service
Table 360
5. Check the Electrical Power to the Communication Adapter Electrical Result: Battery voltage is not present at the service tool
power connector.
A. Check for battery voltage at the service tool connector.
Repair: Inspect the vehicles wiring and fuses. Determine
the cause of the missing voltage. Make the necessary
repairs.
Attempt to establish communication after the electrical

power is at the service tool connector.
Proceed to Test Step 6 if the service tool does not communi-

cate on both data links.
Result: The electronic service tool indicates that the engine

is serviced on the data link.
Repair: Verify that the cable between the service tool con-
nector and the communication adapter is OK. Replace the
cable, if necessary.
Replace the communication adapter if the following condi-

tions are true:
1. There is power at the cables “DATA LINK” connector.
2. The communication adapters “POWER” indicator is not

illuminated.
M0070030-01 577
Service

General information about the electrical power to the ECM
578 M0070030-01
Service
Table 361
6. Check the Electrical Power to the ECM Electrical Result: Battery voltage is missing from a P1 terminal.
power
A. Verify that the keyswitch is ON. Inspect the application wiring and fuses. Determine the
cause of the missing voltage. Make the necessary repairs.
B. Refer to Illustration 251 . Verify that battery voltage is present at
the terminals that are indicated in the Illustration. Be sure to con- Attempt to establish communication after the electrical
nect the voltmeter between the “UNSWITCHED +BATTERY” termi- power is at all of the appropriate P1 terminals. Continue with
nals and the “-BATTERY” terminals. this procedure, if necessary.
C. Verify that battery voltage is present at P1-70. Result: Battery voltage is present at all of the appropriate
P1 terminals.
Proceed to the Test Step 7
7. Try to Establish Communication With a Bypass Harness Harness Result: The electronic service tool communicates on the da-
ta link when the bypass harness is used. There is a problem
A. Connect the communication adapter to the engine ECM with a with the wiring.
2900A038 Wiring Harness (ECM BYPASS) and a T400926 Har-
ness (ELECTRONIC CONTROL MODULE). Repair: Repair the data link. Refer to Troubleshooting, “Data
Link - Test”.
B. Attempt to establish communication.
i06694040
Codes that Inhibit Operation of

Aftertreatment System
Diagnostic Trouble Codes that

Affect the Aftertreatment System
and the Conditions for Clearing the
Code
The following tables list the codes that inhibit the
aftertreatment system either during the current key
cycle or through successive key cycles.
Table 362
Codes That Clear With Each Key Cycle

J1939 PDL Customer Action Clearing Conditions
Code Code
102-18 E1045 (2) Cycle key OFF for 2 minutes and then run engine per Clearing Engine Speed >1400/1500 RPM (MR/HD)
Conditions
108-3 274-3 Cycle the key OFF for 2 minutes then turn the key ON Circuit Check (Auto)
(continued)
M0070030-01 579
Service
(Table 362, contd)
Codes That Clear With Each Key Cycle

Code Code
3242-15 E1008 (1) Cycle key OFF for 2 minutes then START engine and perform a Successful Forced Regeneration
Forced Regeneration
Forced Regeneration
Forced Regeneration
3479-5 2461-5 Cycle key OFF for 2 minutes then START engine and perform a Successful Forced Regeneration
Forced Regeneration
Forced Regeneration
Forced Regeneration
4376-7 3862-7 Service is required, contact local Perkins distributor Troubleshooting procedure and electronic service
tool Service Test Required
Forced Regeneration
Table 363
Codes That Stay Active Through Key Cycles

Codes Codes
3031-18 E1398 Service is required, contact local Perkins distributor Troubleshooting procedure and electronic serv-
ice tool Service Test Required
3216-11 3655-11 Service is required, contact local Perkins distributor Troubleshooting procedure and electronic serv-
(continued)
580 M0070030-01
Service
(Table 363, contd)


Codes Codes
Troubleshooting procedure and electronic serv-
Forced Regeneration
Forced Regeneration
3480-16 E1050 (2) Service is required, contact local Perkins distributor. Troubleshooting procedure and electronic serv-
3487-7 E1040 Cycle the key OFF for 2 minutes then turn the key ON Circuit Check (Auto)
(continued)
M0070030-01 581
Service
(Table 363, contd)


Codes Codes
3703-31 E993 (2) Inhibit Switch is Preventing Regeneration Allow Regeneration
Forced Regeneration
Forced Regeneration
3715-31 E991 (3) Service is required, contact local Perkins dealership Troubleshooting procedure and electronic serv-
Forced Regeneration
Forced Regeneration
4334-7 3090-7 Service is required, contact local Perkins distributor. Troubleshooting procedure and electronic serv-
4360-18 E947 (2) Service is required, contact local Perkins distributor Troubleshooting procedure and electronic serv-
(continued)
582 M0070030-01
Service
(Table 363, contd)


Codes Codes
i06275076 4. Flash program the test ECM with the newest

software that is available.
Test ECM Mode 5. Start the “Test ECM Mode” on the electronic
service tool. Access the feature through the
“Service” menu. The electronic service tool will
“Test ECM Mode” is a feature in the software that can display the status of the test ECM and the hours
be used to help troubleshoot an engine that may
have a fault in the Electronic Control Module (ECM). that are remaining for the “Test ECM Mode” .
This feature allows a standard ECM to be used as a
test ECM. This feature eliminates the need to stock a Note: “Test ECM Mode” can only be activated if the
test ECM. engine serial number has not already been
programmed during normal operation of the ECM. If
1. Search for the latest flash file for the engine. the engine serial number is programmed and the
ECM is not in “Test ECM Mode” , the ECM can never
Note: If a newer software version is available for the be used as a test ECM.
engine, install the newest software on the suspect
ECM. If the new software does not eliminate the fault, 6. Use the “Copy Configuration” feature on the
continue with this procedure. electronic service tool to program the test ECM.
2. Use the “Copy Configuration” feature on the Note: If the “ECM Replacement” feature cannot be
electronic service tool to copy the parameters from used, program the test ECM with the values from the
the suspect ECM. “Parameters Worksheet” and the values from the
Configuration Parameters.
Note: If the “ECM Replacement” feature cannot be
used, record the programmed values into the 7. Program the engine serial number into the test
“Parameters Worksheet” . Also record the system ECM.
Note: The “Test ECM Mode” must be activated
3. Disconnect the suspect ECM. Temporarily connect before the engine serial number is programmed into
the test ECM to the engine. Do not mount the test the ECM.
ECM on the engine.
M0070030-01 583
Service
8. Verify that the test ECM eliminates the fault. Exchanging injectors can help determine if a
combustion problem is in the injector or in the
When the “Test ECM Mode” is activated, an internal cylinder. If two injectors that are currently installed in
timer sets a 24 hour clock. This clock will count down the engine are exchanged between cylinders, the
only while the ECM is powered and the keyswitch is injector trim files can also be exchanged. Press the
in the ON position. After the ECM has counted down “Exchange” button at the bottom of the “Injector Trim
the 24 hour period, the ECM will exit the “Test ECM Calibration” screen on the electronic service tool.
Mode” . The parameters and the engine serial Select the two injectors that have been exchanged
number will be set. and press the “OK” button. The tattletale for the
If the test ECM eliminates the fault, the engine can be injectors that were exchanged will increase by one.
released while the “Test ECM Mode” is still active. 1. Perform the following procedure to download an
Once an ECM has been activated in the “Test ECM injector trim file from PTMI. Otherwise, use the
Mode” , the ECM will stay in the “Test ECM Mode” injector trim file from the CD-ROM that is
until the timer times out. Anytime prior to the “Test packaged with the injector.
ECM Mode” timing out, the “Test ECM Mode” can be
reset to 24 hours. Note: The injector serial number and the injector
confirmation code are located on the injector.
If the ECM is used as a test ECM for more than one
engine, reactivate the “Test ECM Mode” in order to
reset the parameters to default values. Then use the a. Record the injector serial number and the
“Copy Configuration” feature to program the injector confirmation code for each injector.
parameters into the test ECM or manually program
the parameters to the correct values. b. Log in to the Perkins secured web site and go to
PTMI.
i06275078
c. Click on “New Search” and select “Injector e-
Injector Trim File - Install trim File” from the drop-down menu.
d. Enter the serial number for the injector in the

search field.
The electronic service tool is used to load injector
trim files into the Engine Control Module (ECM). e. Download the injector trim file to the PC. Repeat
Injector trim files are available from these sources: this procedure for each injector, as required.
• A CD-ROM that is packaged with each new 2. Establish communication between the electronic
injector and each remanufactured injector service tool and the engine ECM. Refer to
Troubleshooting, “Electronic Service Tools”, if
• Perkins Technical Marketing Information (PTMI) necessary.
Replacing an Injector 3. Select the following menu options on the electronic
service tool:
An injector trim file must be loaded into the ECM if an
injector is replaced. • Service
Replacing the ECM
• Calibrations
The “Copy Configuration” utility on the electronic
service tool copies the injector trim files between two • Injector Trim Calibration
engine control modules. If the “Copy Configuration”
fails, load all of the injector trim files manually into the 4. Select the appropriate cylinder.
new ECM. 5. Click on the “Change” button.
“Injector Trim” is displayed below a 630-2 6. Select the appropriate injector trim file from the PC
Programmed Parameter Fault : Erratic, Intermittent,
or Incorrect. The diagnostic code is displayed on the or the CD-ROM.
electronic service tool. 7. Click on the “Open” button.
Exchanging Injectors 8. Enter the injector confirmation code.
9. Click on the “OK” button.
The injector trim file is loaded into the ECM.
584 M0070030-01
Service
10. Repeat the procedure for each cylinder, as

required.
i06700675
ECM Software - Install

system if the diagnostic code in Table 364 is active.
Table 364
Code Description
The flash file is for a different engine family or for a differ-

ent engine application.
Personality Module : Erratic, Intermit-
631-2 253–2 The engine will not start. Clearing this diagnostic code re-
tent, or Incorrect
quires factory passwords. The personality module code
must be reset to zero.
Flash programming is a method of programming or b. Press the “Browse” button to select the part
updating the flash file in the engine Electronic Control number of the flash file that will be programmed
Module (ECM). The electronic service tool is used to into the ECM.
flash program a file into the memory of the engine
ECM. c. When the correct flash file is selected, press the
“Open” button.
Note: Customer versions of the electronic service
tool do not have the flash programming function. d. Verify that the “File Values” match the
Consult your local Perkins Distributor for assistance. application. If the “File Values” do not match the
application, search for the correct flash file.
NOTICE
If the flash file and engine application are not e. When the correct flash file is selected, press the
matched, engine damage may result. “Begin Flash” button.
1. Obtain the part number for the new flash file. f. The electronic service tool will indicate when
flash programming has been successfully
Note: If you do not have the part number for the flash completed.
file, use “PTMI” on the Perkins secured web site.
6. Access the “Configuration” screen under the
Note: You must have the engine serial number to “Service” menu to determine the parameters that
search for the part number of the flash file. require programming.
2. Connect the electronic service tool to the 7. Start the engine and check for proper operation.
diagnostic connector. Check that there are no active diagnostic codes.
3. Turn the keyswitch to the ON position. Do not start i06700697

the engine.
4. Select “WinFlash” from the “Utilities” menu on the ECM - Replace
Note: If “WinFlash” will not communicate with the Use this procedure when replacing the engine
ECM, refer to Troubleshooting, “Electronic Service Electronic Control Module (ECM), Aftertreatment
Tool Does Not Communicate”. ECM, or Diesel Exhaust Fluid Control Unit (DCU).
5. Flash program the flash file into the ECM.
a. Select the engine ECM under the “Detected

ECMs” .
M0070030-01 585
Service
The engine Electronic Control Module (ECM), Note: If the “Copy Configuration” process fails, the
Aftertreatment ECM, and DCU contain no moving parameters must be obtained elsewhere. Some of
parts. Replacement of the components can be costly. the system configuration parameters are stamped
Replacement can also be a time consuming task. on the engine information plate. The aftertreatment
Follow the troubleshooting procedures in this manual identification information is stamped on the CEM
to ensure that replacing the component will correct identification plate. Most of the parameters must be
the problem. Verify that the suspect component is the obtained from the factory. Parameters that are
cause of the problem. related to customer specified parameters must be
A test ECM can be used to determine if the ECM is obtained from the customer or from the Original
faulty. Refer to Troubleshooting, “Test ECM Mode”. Equipment Manufacturer (OEM).
A4:E4 Engine ECM and A5:E2 2. Removal of the ECM:

Aftertreatment ECM Replacement a. Turn the keyswitch OFF.
NOTICE b. Disconnect both ECM connectors.

If the flash file and engine application are not
matched, engine damage may result. c. Disconnect the ECM ground strap.
Perform the following procedure to replace the A4:E4 d. Remove the mounting hardware at each corner
Engine ECM and A5:E2 Aftertreatment ECM. of the ECM.
1. Record the configuration data. 3. Installation of the replacement ECM:
a. Try to establish communication between the a. Use the old mounting hardware to install the
electronic service tool and the ECM. Proceed to replacement ECM.
Test Step 2 if the electronic service tool does not
communicate with the ECM. b. Connect the ECM ground strap.
b. Print the parameters from the “Configuration” c. Connect both ECM connectors. Refer to
screen on the electronic service tool. If a printer Troubleshooting, “Electrical Connectors -
is unavailable, record all the parameters. Inspect” for the correct torque values.
c. Obtain the customer passwords from the engine 4. Configure the replacement ECM:
owner. Access the customer specified
a. Flash program the latest available flash file into
parameters with the electronic service tool.
the ECM. Refer to Troubleshooting, “ECM
Record the value of each customer parameter.
Software - Install” for the correct procedure.
• Record ECM lifetime
b. Use the electronic service tool to match the
totals.
engine application and the interlock code if the
• Record any logged diagnostic codes. replacement ECM was used for a different
application.
Note: If the customer passwords are not available, Note: Two sets of factory passwords are required
proceed to Troubleshooting, “Customer to program the Aftertreatment parameters.
Passwords” for details that are related to customer
passwords. c. If the “Copy Configuration” process from Step 1.
d was successful, return to the “Copy
d. Use the “Copy Configuration/ECM Configuration/ECM Replacement” screen on the
Replacement” feature that is found under the electronic service tool and select “Program
“Service” menu on the electronic service tool. ECM” . Proceed to Step 4.e when programming
Select “Load from ECM” to copy the is complete.
configuration data from the suspect ECM.
d. If the “Copy Configuration” process from Step 1.
d was unsuccessful, manually program the ECM
parameters. The parameters must match the
parameters from Step 1.d.
e. Program the engine monitoring system, if

necessary.
586 M0070030-01
Service
f. Calibrate the engine speed/timing if there is a DPF Replacement without an Engine

diagnostic code for speed/timing sensor Replacement
calibration. The procedure is in Troubleshooting,
“Timing - Calibrate”. 1. If the DPF has failed, replace the DPF and reset
the engine ash model, Refer to Troubleshooting,
g. If an E1305 (1) or 3483-11 code becomes active
“Service Tool Features, DPF Ash Service” for
after the ECM replacement, Refer to
additional information.
Troubleshooting, “Diesel Particulate Filter
Regeneration Does Not Occur” for instructions
on clearing the code.
CEM Replacement without an Engine
Replacement
Diesel Exhaust Fluid Control Unit
(DCU) Replacement 1. If the complete CEM was replaced, reset the
engine ash model, perform the DOC replacement
Replacement of the DCU does not require the procedure, and perform the SCR replacement
configuration data to be recorded. When the DCU is procedure.
replaced, the flash file is already installed in the new
DCU.
1. Removal of the DCU:
a. Turn the keyswitch to the OFF position.
b. Disconnect the 86-pin and 53-pin connectors.
c. Remove the mounting hardware.

2. Installation of the replacement DCU:
a. Install the previously removed mounting

hardware to the replacement DCU.
b. Connect the 86-pin and 53-pin connectors.
Additional Procedures when

Replacing the Engine, Engine ECM,
Aftertreatment ECM, DCU, or CEM
Engine Replacement or ECM
Replacement without DPF Replacement
If the engine or aftertreatment ECM is replaced, then
determine the most recent cleaning of the DPF.
1. If the diesel particulate filter was cleaned within the
last 500 hours of operation, an ash cleaning
procedure is not required. Reset the engine ash
model, Refer to Troubleshooting, “Service Tool
Features, DPF Ash Service” for additional
information.
2. If the diesel particulate filter was not cleaned within
the last 500 hours of operation, clean the DPF.
Refer to Systems Operation and Testing and
Adjusting, “Diesel Particulate Filter - Clean” for the
correct procedure.
M0070030-01 587
Service
2. Update the CEM serial number with the electronic

service tool.
a. Click “Configuration” .
b. Select “Engine #1 Aftertreatment Controller” .
c. Select “Factory Installed Aftertreatment #1

Indentification Number” .
d. Click the “Change” tab at the bottom of the
screen.
e. Type in the new CEM serial number and click
“OK” .
3. Perform an “Aftertreatment System Functional
Test” in the electronic service tool to verify the
correct operation of the new CEM.
i06700701
DEF Pump - Replace

588 M0070030-01
Service
Table 365
Code Description
PDL Code Comments
Code vary)
Aftertreatment #1 DEF Doser #1 The Diesel Exhaust Fluid Controller (DCU) detects an abnormal temperature sig-
4337-8 3096–8 Temperature : Abnormal Fre- nal from the pump.
quency, Pulse Width, or Period The code is logged.
Aftertreatment #1 DEF Pump #1

The DCU detects an abnormal motor speed signal from the pump.
4374-8 3118–8 Motor Speed : Abnormal Fre-
The code is logged.
quency, Pulse Width, or Period
Aftertreatment #1 DEF Return The DCU detects that the return valve is not responding properly.
4376-7 3862–7
Valve : Not Responding Properly The code is logged.
Table 366
1. 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 2.
purge, reset the code, and reset the DCU.
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 Replace the PETU wiring harness. Proceed to Test Step
corrosion. 2.
2. 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 3.
keyswitch must be OFF for 2 minutes to allow the DEF pump to
purge, reset the code, and reset the DCU. Result: The lines are leaking.
B. Replace the DEF pump. Refer to the Disassembly and As- Make the necessary repairs and repeat the “DEF Dosing
sembly manual for the correct procedure. System Verification Test” .
C. Establish communication between the electronic service tool Proceed to Test Step 3.
and the Diesel Exhaust Fluid Controller #1 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.
3. 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
and the “Engine #1 Aftertreatment Controller” . Result: The “Aftertreatment System Functional Test” was
not successful and additional codes were logged.
Troubleshoot the additional codes, Refer to Troubleshoot-
ing for the correct procedure.
M0070030-01 589
Service

steps are listed.
i06700713
ARD Combustion Air Valve -

Replace
This code will trip if the automated ARD air valve

calibration sweep exceeds the calibration limits and
failed regeneration occurs. The ARD air valve
calibration is automatically controlled by the A5:E2
aftertreatment ECM. The calibration occurs after the
A5:E2 aftertreatment ECM powers up and again
before regeneration starts. Any combustion air valve
faults will prevent the calibration cycle from occurring.
Table 367

PDL Code Comments
Code
The automated ARD Air Valve Calibration sweep has exceeded the calibration
Aftertreatment #1 Air Pressure
3487-13 2489-13 limits AND failed regeneration has occurred.
Control : Out of Calibration
The code is logged.
Table 368
1. Check for Active or Logged Codes Diagnostic Trou- Result: There are no active or logged codes.
ble Codes
A. Establish communication between the electronic service tool Return the unit to service.
and the aftertreatment ECM (A5).
B. Look for active or logged codes. Result: A 3487-13 or 2489-13 code is still active or
logged.
2. Replace the ARD Air Valve Test Passed Result: The ARD Ignition Test passed.
A. Replace the ARD air valve. Return the unit to service.
B. Clear all codes using the electronic service tool. Result: The ARD Ignition Test failed.
C. Perform an ARD Ignition Test using the electronic service tool. Troubleshoot the active codes.
Manual DPF Regeneration must be performed using the electronic
service tool.
590 M0070030-01
Service
i05969972 Check Connectors for Moisture

Electrical Connectors - Inspect and Corrosion
Most electrical faults are caused by poor

connections. The following procedure will assist in
detecting faults with connectors and with wiring. If a
fault is found, correct the condition and verify that the
fault is resolved.
Intermittent electrical faults are sometimes resolved
by disconnecting and reconnecting connectors.
Check for diagnostic codes immediately before you
disconnect a connector. Also check for diagnostic
codes after you reconnect the connector. If the status
of a diagnostic code is changed due to disconnecting
and reconnecting a connector, there are several
possible reasons. The likely reasons are loose
terminals, improperly crimped terminals, moisture,
corrosion, and inadequate mating of a connection.
Follow these guidelines:
• Always use a CH11155 Crimp Tool to service

Deutsch HD and DT connectors. Never solder the
terminals onto the wires.
Detail A illustrates the incorrect angle of wire entry
• Always use a 28170079 Wedge Removal Tool in into the connector. The wire should enter the
order to remove wedges from DT connectors. connector at a perpendicular angle. (typical example)
Never use a screwdriver to pry a wedge from a
connector. Inspect all the harnesses. Ensure that the routing of
the wiring harness allows the wires to enter the face
• Always use a breakout harness for a voltmeter of each connector at a perpendicular angle.
probe or a test light. Never break the insulation of Otherwise, the wire will deform the seal bore. The
damaged seal will create a path for the entrance of
a wire in order to access to a circuit for moisture. Verify that the seals for the wires are
measurements. sealing correctly.
• If a wire is cut, always install a new terminal for the
repair.
• Determine if the problem is intermittent. If the
problem is intermittent, attempt to test the circuit
before you disconnect any electrical connectors.
The test will help identify the root cause of
intermittent problems. The “Wiggle Test” on the
electronic service tool may be able to test the
circuit. Refer to the documentation that
accompanies the electronic service tool. Perform
the wiggle test on the circuit, when possible.
Otherwise, continue with this procedure.
M0070030-01 591
Service

Diagram for the installation of a connector plug Seal for the ECM connector (typical example)
(typical example)
(1) Electronic Control Module (ECM) connector Disconnect the suspect connector and inspect the
(2) Correctly inserted plug connector seal. Ensure that the seal is in good
(3) Incorrectly inserted plug condition. If necessary, replace the connector.
Ensure that the sealing plugs are in place. If any of Thoroughly inspect the connectors for evidence of
the plugs are missing, replace the plug. Ensure that moisture entry.
the plugs are inserted correctly into the connector.
Note: Some minor seal abrasion on connector seals
is normal. Minor seal abrasion will not allow the entry
of moisture.
If moisture or corrosion is evident in the connector,
the source of the moisture entry must be found. The
source of the moisture entry must be repaired. If the
source of the moisture entry is not repaired, the fault
will recur. Simply drying the connector will not fix the
fault. Check the following items for the possible
moisture entry path:
• Missing seals
• Incorrectly installed seals
• Nicks in exposed insulation

Seal for a three-pin connector (typical example) • Improperly mated connectors
Moisture can also travel to a connector through the
inside of 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.
Check the Wires for Damage to the

Insulation
Carefully inspect each wire for signs of abrasion,
nicks, and cuts.
Inspect the wires for the following conditions:
592 M0070030-01
Service
• Exposed insulation Check Individual Pin Retention into

• Rubbing of a wire against the engine the Socket
• Rubbing of a wire against a sharp point
Check all of the fasteners for the harness and the
ECM in order to verify that the harness is correctly
secured. Also check all of the fasteners in order to
verify that the harness is not compressed. Pull back
the harness sleeves in order to check for a flattened
portion of wire. A fastener that has been
overtightened flattens the harness. This damages the
wires that are inside the harness.
Inspect the Connector Terminals

Visually inspect each terminal in the connector. Verify
that the terminals are not damaged. Verify that the
terminals are correctly aligned in the connector and
verify that the terminals are correctly located in the Illustration 258 g01131604
connector. Diagram for testing pin retention (typical example)
Perform a Pull Test on Each Wire Verify that the sockets provide good retention for the
Terminal Connection pins. Insert a new pin into each socket one at a time
in order to check for a good grip on the pin by the
socket.
Check the Locking Mechanism of

the Connectors
Ensure that the connectors lock correctly. After you
lock the connectors, ensure that the two halves
cannot be pulled apart.
Verify that the latch tab of the connector is correctly
latched. Also verify that the latch tab of the connector
returns to the locked position.
Check the Allen Head Screws on

the Connectors
Illustration 257 g01131435 Visually inspect the allen head screws for the ECM
Receptacle lock wedge (typical example) connectors. Ensure that the threads on each allen
head screw are not damaged.
Ensure that the locking wedge for the connector is
installed correctly. Terminals cannot be retained
inside the connector if the locking wedge is not
installed correctly.
Perform the 45 N (10 lb) pull test on each wire. Each
terminal and each connector should easily withstand
45 N (10 lb) of tension and each wire should remain
in the connector body. This test checks whether the
wire was correctly crimped in the terminal and
whether the terminal was correctly inserted into the
connector.

Allen head screw for the 120 pin ECM connector
(typical example)
M0070030-01 593
Service
Torque the allen head bolt for the 120 pin ECM If an intermittent fault exists, the status will be
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in). highlighted and an audible beep will be heard.
i06700771
Cooling Fan - Calibrate
Use this procedure if the diagnostic code in Table

369 is active.

Allen head screw for the 70 pin ECM connector
(typical example)
Torque the allen head screw for the 70 pin ECM

connector to 6.0 + 1.5 - 1.0 N·m (55 + 13 - 9 lb in).

Allen head screw for the 40 pin customer connector
and the 70 pin customer connector (typical example)
Torque the allen head screw for the 40 pin customer

connector and the 70 pin customer connector to
2.25 ± 0.25 N·m (20 ± 2 lb in).
Perform the Wiggle Test on the

electronic service tool
Select the “Wiggle Test” from the diagnostic tests on
Choose the appropriate group of parameters to
monitor.
Press the “Start” button. Wiggle the wiring harness in
order to reproduce intermittent faults.
594 M0070030-01
Service
Table 369
Code Description
Fan Drive Bypass Command Status : Out of

Calibration
The Electronic Control Module (ECM) supplies

current to the engine fan control solenoid. The engine
fan control solenoid controls the pressure to the fan
pump by allowing oil to bypass the fan pump. The fan
pump drives the fan. For accuracy, the ECM must
determine the relationship between the current to the
engine fan control solenoid and the actual fan speed.
The electronic service tool enables the user to
calibrate the current to a known fan speed manually.
Note: The ECM will use a nominal current to drive
the engine fan control solenoid on the initial
calibration. The ECM uses the last calibrated value
as the starting point on subsequent calibrations.
1. Select the “Service” tab and select “Calibrations” .

Start the “Fan Calibration” .
2. Meet the required conditions to proceed with the
calibration. Follow the directions that are provided
on the electronic service tool. Proceed by pressing
the “Next” button.
3. Measure actual fan speed with the following
service tool
• T402260 Tachometer
a. If actual fan speed matches the fan speed on

the electronic service tool, press the “Next”
button.
b. Actual fan speed may not match the fan speed
on the electronic service tool. The current must
then be decremented or incremented to change
fan speed.
4. When actual fan speed matches the fan speed on
the electronic service tool, the calibration is
complete. Follow the directions that are provided
on the electronic service tool.
i06841079
Timing - Calibrate
Use this procedure if the diagnostic code in

Table 370 is active.
M0070030-01 595
Service
Table 370
Code Description
The wiring to the sensors has the wrong

637-11 261-11 Engine Timing Offset fault
polarity.
A timing calibration is required for a new

engine, replacing an Electronic Control
Engine Timing Calibration : Calibration
637-13 261-13 Module (ECM) that fails to communicate or
Required
following work on the front gear train, the
camshaft, or the crankshaft.
If a 261-11 or 637-11 diagnostic code is active, verify

that the wiring is installed correctly to the engine
speed/timing sensors.
The ECM can calibrate the mechanical differences
between the Top Center (TC) of the flywheel and the
TC of the timing gear on the camshaft. A transducer
signals the TC of the flywheel to the ECM when a
notch on a counterweight passes by the transducer.
The engine speed/timing sensor signals the TC of the
timing gear to the ECM. Any offset between the TC of
the flywheel and the TC of the timing gear is stored
into the memory of the ECM.
Note: A timing calibration will not increase the

available engine power.
Table 371 lists the special tools that are required to
perform this procedure.
Table 371
Required Special Tools
GE50039 Transducer Adapter
GE50038 Transducer
GE50040 Cable as
T400930 Harness (1)

(1) This item is not required if the engine harness has a connector Illustration 262 g03048383
for timing calibration. (A) Timing mark
(B) Idler gear
596 M0070030-01
Service
Table 372
Diagnostic code Result: After starting the engine, the code is still
1. Check the Gear Train Timing present.
The camshaft gear will be off a half tooth if the engine is timed Proceed to Test Step 2.
when Cylinder # 6 is at Top Dead Center (TDC). The engine
MUST be timed when Cylinder #1 is at TDC. This could be pos- Result: After starting the engine, the code did not
sible anytime you do not time the engine at the crank to idle return.
gear mesh.
Note: Remove the rocker arms before rotating the engine to
prevent piston/valve damage from occurring.
A. If the engine is at TDC for cylinder 6, remove cam idler gear (B)
and rotate the crankshaft 360 degrees and repin the flywheel.
B. Install idler gear (B).
C. Check timing mark (A).
D. Rotate the engine by hand 360° to ensure that the engine rotates
freely. If the engine does not rotate freely, the engine is not timed
correctly. Remove the front housing and check all timing marks. Re-
fer to Systems Operation, Testing and Adjusting, “Gear Group
(Front) - Time” for the correct procedure.
E. Connect to the electronic service tool and clear the DTC.
F. Start the engine.
Table 373
Crankshaft Rotation
Engine Model Number of Degrees Direction of Rotation
2206F 75 Normal Rotation
2506F 60 Opposite Normal Rotation
2806F 30 Opposite Normal Rotation
Table 374
Location of the Timing Calibration Port
Engine Model Crankshaft Counterweight Engine Location

2206F 8 Left Side
2506F 2 Left Side
2806F 2 Left Side
M0070030-01 597
Service
Table 375
2. Install the Transducer Adapter Transducer Result: The transducer adapter was installed.
adapter
A. Remove the electrical power from the ECM. Proceed to Test Step 3.
B. Use the appropriate engine turning tool to put either the No. 1
piston or the No. 6 piston at the top center. Refer to the Systems
Operation, Testing and Adjusting.
C. Refer to Table 373 . After the top center position has been lo-
cated, rotate the crankshaft for the number of degrees that is appli-
cable to your engine model. Be sure to rotate the crankshaft in the
direction of rotation that is specified in the Table.
D. Refer to Table 374 . Locate the engines timing calibration port.
E. Remove the plug from the timing calibration port.
F. Thread the transducer adapter into the port
3. Install the Transducer Transducer Result: The transducer was installed.
If the crankshaft is not in the correct position when the trans- Proceed to Test Step 4.
ducer is installed, the transducer will be damaged when the en-
gine is started.
A. Apply clean engine oil to a T400931 O-Ring Seal. Install the O-

ring seal on the end of the GE50038 Transducer.
B. Push the transducer through the transducer adapter until the

transducer contacts the crankshaft counterweight.
C. Withdraw the transducer 1 mm (0.4 inch)and hand tighten the

nut on the adapter sleeve to secure the transducer. Move the O-ring
seal against the adapter.
598 M0070030-01
Service

Electronic Control Module
Table 376
Terminal Locations for Connection of the T400930 Harness
ECM Type ADEM 4
Connector P2 P1
Timing Calibration + 26 24
(White)
(Terminal 1) Location
Timing Calibration - 36 25
(Yellow)
(Terminal 2) Location
M0070030-01 599
Service
Table 377
4. Connect the GE50040 Cable as Wiring Result: The wiring is installed correctly.
A. If the engine harness is equipped with a connector for timing cali- Proceed to Test Step 5.
bration, connect the GE50040 Cable as to the connector for timing
calibration and to the transducer.
B. If the engine harness is not equipped with a connector for timing

calibration, or the connector is not easily accessible, a connector
can be installed. The connector can be installed on either ECM
connector.
C. Refer to Illustration 263 to determine the type of engine ECM. Al-

so, determine the ECM connector that is easily accessible.
D. Refer to Table 376 to determine the proper terminal locations for

the connector that is easily accessible.
E. Remove the sealing plugs from the appropriate terminals. Do not

discard the sealing plugs. The sealing plugs may be reinstalled
when the timing calibration is complete.
F. Install the WH(White)wire of the T400930 Harness into the ap-

propriate location.
G. Install the YL(Yellow)wire of the T400930 Harness into the ap-

propriate location. Disregard the pin-outs on the label of the
harness.
H. Ensure that each wire is installed into the correct location. The
timing calibration will not be successful if the wires are installed
incorrectly.
5. Check for Diagnostic Codes Diagnostic Result: There are active codes other than a 261-13 or
codes 637-13 diagnostic code.
Refer to Troubleshooting, “Electronic Service Tools”. Troubleshoot the active diagnostic other than the 261-
13 or 637-13 diagnostic codes.
B. Start the engine and run the engine until the engine is at the nor-
mal operating temperature. Result: There are no active codes other than a 261-13
or 637-13 diagnostic code.
C. Check for active diagnostic codes. Wait at least 30 seconds in or-
der for the codes to become active. Proceed to Test Step 6.
The engine must not have any active diagnostic codes during
the timing calibration except for a 261-13 or 637-13 diagnostic
code.
600 M0070030-01
Service
Table 378
6. Calibrate the Timing Timing Result: The timing calibration was successful.
calibration
A. After the engine has warmed up, access the “Timing Calibration” Return the unit to service.
screen on the electronic service tool. Access the following display
screens in order: Result: The timing calibration was not successful.
· Service The following conditions can cause the timing calibra-

tion to fail:
· Calibrations
1. The crankshaft and camshaft gears have been reas-
· Timing Calibration sembled incorrectly.
B. Set the engine speed to 1100 ± 50 rpm. The engine speed must 2. The timing calibration probe is not installed correctly.
be steady within this rpm range in order for the calibration to be
successful. 3. The engine speed is not correct and the engine
speed is unstable. If the engine speed is unstable, refer
C. To calibrate the timing, select “Continue” on the electronic service to Troubleshooting, “Engine Misfires, Runs Rough, or Is
tool. Wait until the electronic service tool indicates that the timing is Unstable”.
calibrated.
4. There is a problem with the transducer or with the ca-
D. Perform the following procedure if the electronic service tool indi- bles. Obtain a new transducer and/or a new cable and
cates that the timing is calibrated: repeat the timing calibration.
1. Set the engine speed to low idle. 5. There is an active 190-8 code or an active 723-8
code. Troubleshoot the active codes before calibration.
2. Disconnect the GE50040 Cable as before you exit the “Timing
Calibration” screen. Otherwise, diagnostic codes may be activated. Correct any of the above conditions and repeat the cali-
bration procedure.
3. Exit the “Timing Calibration” screen on the electronic service tool.
4. Remove the electrical power from the ECM.
5. Remove the transducer and remove the transducer adapter.
6. Install the plug into the timing calibration port.
7. If a T400930 Harness, either remove the harness or perma-

nently install the harness for future use. If the harness is removed,
install the sealing plugs into the unused cavities of the ECM connec-
tor. Otherwise, moisture and debris will enter the connector.
8. If the harness is permanently installed, fasten the harness to the

existing engine wiring harness with cable ties. Also, install a
T400932 Receptacle and two 2900A011 Seal Plugs on the P400
timing calibration probe connector to prevent moisture and debris
from entering the connector.
M0070030-01 601
Index Section
Index
A Recommended Actions .................................. 146
Coolant Level - Test........................................... 356
Acceleration Is Poor or Throttle Response Is Coolant Level Is Low ......................................... 148
Poor .................................................................89 Probable Causes ........................................... 148
Probable Causes .............................................89 Recommended Actions .................................. 148
Recommended Actions ....................................89 Coolant Pressure Is Low .................................... 150
Aftertreatment Identification Module - Test........... 325 Coolant Temperature Is High.............................. 154
Air Shutoff - Test................................................ 320 Probable Causes ........................................... 154
Alternator Problem ..............................................91 Recommended Actions .................................. 154
Probable Causes .............................................91 Coolant Temperature Is Low .............................. 157
Recommended Actions ....................................91 Probable Causes ........................................... 157
ARD Combustion Air - Test ................................ 330 Recommended Actions .................................. 157
ARD Combustion Air Valve - Replace ................. 589 Cooling Fan - Calibrate ...................................... 593
ARD Combustion Supply Air Pressure Is Low........93 Cooling Fan Control - Test ................................. 359
ARD Failed to Ignite ............................................97 Cooling Fan Is Always ON ................................. 159
ARD Fuel Pressure Is High ................................ 106 Probable Causes ........................................... 159
ARD Fuel Pressure Is Low ................................. 115 Recommended Actions .................................. 160
ARD Fuel Supply - Test...................................... 337 Cooling Fan Reversing - Test ............................. 362
ARD Ignition - Test ............................................ 342 Cooling Fan Speed - Test................................... 364
ARD Is Disabled................................................ 126 Crankcase Fumes Disposal Tube Has Oil
ARD Loss of Combustion................................... 130 Draining.......................................................... 160
ARD Nozzle Heater - Test .................................. 347 Probable Cause............................................. 160
ARD Temperature Is Low ................................... 137 Recommended Actions .................................. 161
Crankcase Pressure Is High............................... 161
B Probable Causes ........................................... 162
Recommended Actions .................................. 162
Battery Problem ................................................ 142 Crankcase Pressure Is Low ............................... 164
Probable Causes ........................................... 142 Probable Causes ........................................... 165
Recommended Actions .................................. 142 Recommended Actions .................................. 166
Customer Passwords ........................................ 571
Cylinder Is Noisy ............................................... 166
C Probable Causes ........................................... 166
Circuit Tests...................................................... 320 Recommended Actions .................................. 166
Clean Emissions Module Has High Oxygen
Level .............................................................. 143 D
Codes that Inhibit Operation of Aftertreatment
System ........................................................... 578 Data Link - Test ................................................. 367
Diagnostic Trouble Codes that Affect the Data Link Configuration Status - Test .................. 376
Aftertreatment System and the Conditions for DEF Control Module Power - Test....................... 379
Clearing the Code ........................................ 578 DEF Control Module Temperature Is High ........... 168
Component Location ........................................... 11 DEF Does Not Purge ......................................... 170
ARD Head and Dosing Unit Overview................24 DEF Line Heater - Test ...................................... 383
CEM Control Panel ..........................................23 DEF Module Does Not Respond......................... 171
Clean Emission Module (CEM) Side View..........22 DEF Pressure Is High ........................................ 174
DEF Dosing Unit (Injector) ................................29 DEF Pressure Is Low......................................... 177
DEF Dosing Unit (Left Side)..............................28 DEF Pump - Replace......................................... 587
DEF Dosing Unit (Right Side)............................27 DEF Pump Motor - Test ..................................... 391
DEF Dosing Unit (Top) .....................................26 DEF Pump Pressure Sensor - Test ..................... 395
Electronic Control Circuit Diagram..................... 11 DEF Pump Sensor Supply - Test ........................ 397
Sensor Locations .............................................14 DEF Return Valve - Test..................................... 400
View A ............................................................16 DEF Tank Level Is Low ...................................... 185
View B ............................................................17 DEF Tank Sensor - Test ..................................... 403
View C ............................................................18 DEF Tank Temperature Is High........................... 188
View D ............................................................19 DEF Temperature Is Low ................................... 192
View E ............................................................20 Desulfation Is Frequent...................................... 196
View F ............................................................21 Diagnostic Capabilities ........................................31
Configuration Parameters ....................................38 Diagnostic Codes.............................................31
Check Programmable Parameters 630–2 (268- Diagnostic Trouble Codes....................................41
2) ..................................................................40 Diagnostic Trouble Codes in J1939 Order..........41
Coolant Contains Fuel ....................................... 144 Diagnostic Trouble Codes in Perkins Data Link
Probable Causes ........................................... 144 (PDL) Code Order ..........................................56
Recommended Actions .................................. 145 Diesel Particulate Filter Collects Excessive
Coolant Contains Oil ......................................... 145 Soot ............................................................... 200
Probable Causes ........................................... 145
602 M0070030-01
Index Section
Diesel Particulate Filter Has Changed Engine Overcrank Occurrence ........................... 227
Regeneration Interval ...................................... 203 Probable Causes ........................................... 228
Diesel Particulate Filter Has High Ash Load......... 206 Recommended Actions .................................. 228
Diesel Particulate Filter Has High Inlet Pressure .. 207 Engine Overspeeds........................................... 230
Diesel Particulate Filter Has Low Inlet Pressure... 209 Probable Causes ........................................... 230
Diesel Particulate Filter Regeneration ...................29 Recommended Actions .................................. 230
Regeneration...................................................29 Engine Shutdown Occurrence............................ 231
Selective Catalyst Reduction (SCR) ..................29 Probable Causes for a E1466 or 6588-31
Diesel Particulate Filter Temperature Is High ....... 210 Code ........................................................... 232
Diesel Particulate Filter Temperature Is Low ........ 213 Probable Causes for a E265 Code .................. 232
Probable Causes for a E268, E369, or 5272-31
Code ........................................................... 232
E Engine Shutdown Occurs Intermittently............... 234
ECM - Replace ................................................. 584 Probable Causes ........................................... 234
A4:E4 Engine ECM and A5:E2 Aftertreatment Recommended Actions .................................. 235
ECM Replacement ....................................... 585 Engine Shutdown While Idling ............................ 237
Additional Procedures when Replacing the Engine, Probable Causes ........................................... 237
Engine ECM, Aftertreatment ECM, DCU, or Recommended Actions .................................. 237
CEM ........................................................... 586 Engine Stalls at Low RPM.................................. 237
Diesel Exhaust Fluid Control Unit (DCU) Probable Causes ........................................... 237
Replacement ............................................... 586 Recommended Actions .................................. 238
ECM Software - Install ....................................... 584 Engine Top Speed Is Not Obtained ..................... 240
ECM Will Not Accept Factory Passwords ............ 571 Probable Causes ........................................... 240
Probable Causes ........................................... 571 Recommended Actions .................................. 240
Recommended Actions .................................. 572 Engine Vibration Is Excessive ............................ 243
Electrical Connectors ..........................................32 Probable Causes ........................................... 243
Connectors for the Electronic Control Module Recommended Actions .................................. 244
(ECM) ...........................................................32 Ether Starting Aid - Test ..................................... 409
Injector Connectors..........................................35 Event Codes .......................................................72
Sensor Connectors ..........................................36 Active Event Codes..........................................87
Electrical Connectors - Inspect ........................... 590 Clearing Event Codes ......................................88
Check Connectors for Moisture and Event Codes in J1939 Code Order ....................72
Corrosion .................................................... 590 Event Codes in Perkins Data Link (PDL) Code
Check Individual Pin Retention into the Order ............................................................79
Socket......................................................... 592 Logged Event Codes........................................88
Check the Allen Head Screws on the Parts of the Event Code....................................87
Connectors.................................................. 592 Troubleshooting...............................................88
Check the Locking Mechanism of the Exhaust Balance Valve - Test ............................. 413
Connectors.................................................. 592 Exhaust Has Excessive Black Smoke ................. 244
Check the Wires for Damage to the Probable Causes ........................................... 244
Insulation..................................................... 591 Recommended Actions .................................. 245
Inspect the Connector Terminals ..................... 592 Exhaust Has Excessive White Smoke................. 246
Perform a Pull Test on Each Wire Terminal Probable Causes ........................................... 246
Connection .................................................. 592 Recommended Actions .................................. 247
Perform the Wiggle Test on the electronic service Exhaust System Contains Coolant...................... 250
tool ............................................................. 593 Probable Causes ........................................... 250
Electrical Power Supply - Test ............................ 406 Recommended Actions .................................. 250
Electronic Service Tool Does Not Communicate .. 572 Exhaust System Contains Fuel........................... 251
Electronic Service Tools.........................................7 Probable Causes ........................................... 251
Optional Service Tools........................................7 Recommended Actions .................................. 252
Perkins Electronic Service Tool ..........................8 Exhaust System Contains Oil ............................. 254
Service Tools.....................................................7 Probable Causes ........................................... 254
Electronic System Overview.................................10 Recommended Actions .................................. 254
Engine Cranks but Does Not Start ...................... 216 Exhaust Temperature Is High ............................. 256
Engine Does Not Crank ..................................... 219 Probable Causes ........................................... 256
Engine Has Early Wear...................................... 220
Probable Causes ........................................... 220 F
Engine Has Mechanical Noise (Knock) ............... 222 Factory Passwords............................................ 571
Probable Causes ........................................... 222 Fuel Consumption Is Excessive.......................... 260
Recommended Actions .................................. 222 Probable Causes ........................................... 260
Engine Misfires, Runs Rough or Is Unstable........ 225 Recommended Actions .................................. 260
Probable Causes ........................................... 225 Fuel Filter Is Restricted ...................................... 262
Recommended Actions .................................. 225 Probable Causes ........................................... 262
Engine Monitoring System ...................................30 Fuel Pressure Is High ........................................ 263
Viewing or Changing the Settings of the Monitoring Fuel Pressure Is Low ......................................... 269
System..........................................................30 Fuel System Water Separator Has Water ............ 273
M0070030-01 603
Index Section
Troubleshooting Procedure............................. 274 R

Fuel Temperature Is High................................... 275
Retarder - Test .................................................. 437
G
S
General Information ..............................................5
Application Interface ..........................................5 SCR Catalyst Inlet Temperature Sensor - Test ..... 444
Clean Emissions Module (CEM)..........................5 SCR Warning System Problem........................... 312
Electronic Control System ..................................5 Associated Codes.......................................... 312
Fault Detection and Reporting.............................6 Engine Emissions Operator Inducement Service
Important Safety Information...............................5 Mode Override ............................................. 316
Overview...........................................................5 Operator Level Inducement ............................ 312
Troubleshooting.................................................6 Sensor (Data Link Type) - Test ........................... 451
Sensor Calibration Required - Test ..................... 447
Sensor Signal (Analog, Active) - Test .................. 454
I Sensor Signal (Analog, Passive) - Test ............... 468
Sensor Supply - Test ......................................... 474
Idle Speed Is High ............................................. 279 Service............................................................. 517
Probable Causes ........................................... 280 Service Tool Error Identifiers .............................. 565
Recommended Actions .................................. 280 Service Tool Features........................................ 517
Important Safety Information ..................................2 Active Diagnostic Codes................................. 518
Indicator Lamp Problem..................................... 280 Active Event Codes........................................ 519
Probable Causes ........................................... 280 Aftertreatment History .................................... 549
Recommended Actions .................................. 280 Calibrations ................................................... 523
Injector Solenoid - Test ...................................... 420 Diagnostic Tests ............................................ 520
Injector Trim File - Install .................................... 583 Dyno Mode.................................................... 528
Inlet Air Is Restricted ......................................... 281 Histogram Screens ........................................ 557
Intake Manifold Air Pressure Is Low .................... 282 Logged Diagnostic Codes............................... 519
Intake Manifold Air Temperature Is High.............. 285 Logged Event Codes...................................... 519
Introduction ..........................................................5 Override Parameters...................................... 517
Service Procedures........................................ 532
System Troubleshooting Settings .................... 518
N Shutdown (Ground Level) - Test ......................... 477
NOx Conversion Is Low ..................................... 288 Solenoid Valve - Test ......................................... 480
NOx Reduction System (NRS) - Test .................. 427 Speed Control - Test.......................................... 489
NOx Sensor - Test ............................................. 435 Speed/Timing - Test .......................................... 492
NRS Exhaust Gas Temperature Is High .............. 293 Switch Circuits - Test ......................................... 496
Symptom Troubleshooting ...................................89
System Overview ................................................10
O Other ECM Functions for Performance ..............10
Passwords ...................................................... 11
Oil Consumption Is Excessive ............................ 297 Programmable Parameters...............................10
Probable Causes ........................................... 297 System Operation ............................................10
Oil Contains Coolant ......................................... 299
Probable Causes ........................................... 299 T
Oil Contains Fuel .............................................. 302 Table of Contents ..................................................3
Measuring Fuel Dilution.................................. 302 Test ECM Mode ................................................ 582
Probable Causes ........................................... 302 Timing - Calibrate .............................................. 594
Recommended Actions .................................. 302 Troubleshooting Section ........................................5
Oil Pressure Is Low ........................................... 303
Probable Causes ........................................... 304
Recommended Actions .................................. 304 V
Oil Temperature Is High ..................................... 307 Valve Lash Is Excessive .................................... 316
Probable Causes ........................................... 308 Probable Causes ........................................... 316
Recommended Actions .................................. 308 Recommended Actions .................................. 316
Valve Rotator or Spring Lock Is Free................... 318
Probable Cause............................................. 318
P Recommended Actions .................................. 319
Power Is Intermittently Low or Power Cutout Is Variable Valve Actuator - Test............................. 498
Intermittent...................................................... 309 Variable Valve Actuator Response - Test ............. 503
Probable Causes ........................................... 309
W
Water in Fuel - Test ........................................... 514
Welding Precaution ...............................................6
©2017 Perkins Engines Company Limited
All Rights Reserved

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M0070030-01 (en-us)

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

DEF Pump Sensor Supply - Test ........................ 397

Troubleshooting Section Electronic Control System

General Information • Torque curves

Fault Detection and Reporting • High DPF #1 Soot Loading

28170079 Wedge Removal Tool

T400920 Wire Removal Tool (14-GA TO 18-GA, RED)

CH11155 Crimp Tool (12−AWG TO 18−AWG)

T400922 Adapter Cable As (40-PIN BREAKOUT)

GE50037 / Adapter Cable As (70-PIN BREAKOUT)

T400924 Adapter Cable As (120-PIN BREAKOUT)

• Programmable parameter settings Connecting the Electronic Service Tool

• Graphs (real time)

Connecting the Electronic Service Tool

Electronic System The ECM adjusts timing for optimum engine

Timing Considerations Programmable Parameters

System configuration parameters are set at the

Electronic Control Circuit Diagram

Electronic Service Tool Dis- Troubleshooting Guide Com-

Engine charge air cooler #1 out- Charge air cooler outlet

ARD fuel flow diverter actuator ARD fuel diverter valve

EGR intake pressure (absolute) NRS absolute pressure sensor

EGR temperature NRS temperature sensor

EGR valve NRS actuator

DPF #1 intake temperature DPF inlet temperature sensor

ARD fuel pressure #1 Pilot fuel pressure sensor

ARD fuel pressure #2 Main fuel pressure sensor

Aftertreatment #1 ignition ARD ignition coil

Aftertreatment #1 secondary air Combustion air inlet pressure

Refer to Table 4 when referencing electronic service

(1) Fuel temperature sensor (2) Fuel pressure sensor

(1) Terminating resistor (3) Crankcase pressure sensor

(1) Primary speed/timing sensor (2) A/C and alternator connector

Clean Emission Module (CEM) Side

CEM Control Panel

ARD Head and Dosing Unit Overview

(10) Diverter valve (11) Priming Pump (12) Pressure regulator

DEF Dosing Unit (Top)

DEF Dosing Unit (Right Side)

DEF Dosing Unit (Left Side)

DEF Dosing Unit (Injector)

(1) DEF Injector (2) Coolant Lines

i06633447 Selective Catalyst Reduction (SCR)

Connectors for the Electronic Control

Connector at the Injector

Sensor Connectors Connectors for the Termination Resistor

Analog Sensor Connector (active)

Analog Sensor Connector (passive)

Engine Speed/Timing Connector

Ampseal Connector (typical)

Deutsch Connectors (typical)

Use this procedure if the diagnostic code in Table 6 is

The electronic service tool can be used to view

1. Connect to the electronic service tool.

Check Programmable Parameters

If a programmable parameter has not been

Diagnostic Trouble Codes

Diagnostic Trouble Codes

Diagnostic Trouble Codes in J1939

- 544–2 Troubleshooting, “Cooling Fan Speed - Test”

- 544–8 Troubleshooting, “Cooling Fan Speed - Test”