5032639 JOHNSON *BREAKER Assy

Introduction
The EPA has mandated that a DEF quality sensor must be installed on all engines built in 2017 or after. This new DEF quality sensor is integrated into the DEF header inside the DEF tank. The new style DEF header utilizes CAN C communication, so the wiring to the DEF header has been slightly modified on product going forward. However, the DCU remains compatible to both setups with the latest 507-7605 Engine Software. As part of the DEF quality sensor implementation, a new configuration parameter setting is used on the engine ECM in Cat® Electronic Technician (ET) to identify whether a DEF quality sensor is "installed" or "not installed". Below are some different fault codes for incompatible hardware and configuration setting as well as different service scenarios that may be encountered with this change and how to resolve any issues in these particular service scenarios. In addition to this Special Instruction, there is a video detailing these changes posted on Cat Channel 1.Channel1 Video
Note: A CWS login is required to access Caterpillar Channel1. Scan the QR code below with a QR enabled device or copy the link that follows.
Illustration 1 g06462430Reference: For more information, refer to "Diesel Exhaust Fluid Quality Sensor" on Caterpillar Channel1.https://channel1.mediaspace.kaltura.com/media/0_qyokrphe
Fault Codes When Parts/Settings Are Not Compatible
DEF quality header not installed but configuration set to installed.
Table 1
J1939 Code and Description CDL Code and Description
1235-9
J1939 Network #3 : Abnormal Update Rate 5856-9
J1939 Network #3 : Abnormal Update Rate DEF quality header installed but configuration set to not installed.
Table 2
J1939 Code and Description CDL Code and Description
1761-3
Aftertreatment 1 Diesel Exhaust Fluid Tank Level : Voltage Above Normal 3130-3
Aftertreatment #1 SCR Catalyst Reagent Tank #1 Level Sensor : Voltage Above Normal
3031-3
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature : Voltage Above Normal 3134-3
Aftertreatment #1 SCR Catalyst Reagent Tank #1 Temperature Sensor : Voltage Above Normal DEF Quality Sensor Service Scenarios
Listed below are the different examples of when the DEF Quality Sensor and associated components are needed.Replacement Industrial Engine (Built in 2016 or Before)
If these engines are replaced with an engine built in 2017 or after, the following updates will be required:
Updating to a DEF Quality Sensor by installing a new DEF Header
Wiring Harness
DCU Software
Change configuration status to "Installed" in Cat ETReplacement Machine Engine (Built in 2016 or Before)
If this engine is replaced with an engine built in 2016 or a previous Engine Arrangement Complete (EAC) engine, no other changes are needed.Confirm that the "DEF Quality Sensor" configuration is set to "Not Installed" in Cat ET.Replacement Machine Engine (Built in 2016 or Before)
If the engine is replaced with the latest EAC the following updates will be required:
Update to a DEF Quality Sensor by installing a new DEF header
Wiring harness
DCU Software
Change configuration status to "Installed" in Cat ETReplacement Engine (Built in 2017 or After)
Replace the engine with the latest EAC.Installing the DEF Quality Sensor on Engines Built in 2016 or Before
If installing the DEF Quality Sensor on engine built in 2016 or before, the following must be updated as well:
DCU software update
PETU wiring harness update
"DEF Quality Sensor" configuration changed to "Installed" in Cat ETReplacing the Dosing Control Unit (DCU)
There is not an effect when replacing just the DCU. The software and hardware for the DCU is compatible with both types of DEF header.Replacing the Engine Electronic Control Module (ECM)
There is no effect when using an ECM replacement file.If the engine ECM is replaced without an ECM replacement file, the "DEF Quality Sensor" configuration in Cat ET will default to "Not Installed". If the machine utilizes a DEF Quality Sensor, that configuration will need to be changed to "Installed". This change will require Factory Password System (FPS) to work.Replacing the Aftertreatment Electronic Control Module (ECM)
There is not an effect on the system. The "DEF Quality Sensor" configuration is saved in the engine ECM.Replacing the Wiring Harness
There is not an effect for replacing the wiring harness. The new and previous wiring harness part numbers are available, order the same part number that is removed.