0324641 JOHNSON CUP

Stopping the engine immediately after the engine has been working under load can result in overheating of DEF system components.Refer to the Operation and Maintenance Manual, "Engine Stopping" procedure to allow the engine to cool and to prevent excessive temperatures in the turbocharger housing and the DEF injector.
Allow at least 2 minutes after the engine has stopped before you turn the battery disconnect switch to OFF. Disconnecting the battery power too soon will prevent purging of the DEF lines after the engine is shut down.
Warning Strategy
The engine ECM will have software enabled in order to warn, derate, and only operate a low idle. This software is in order to keep the engine emissions complaint.Warning Indicators
The warning indicators consist of a level gauge for the DEF, a low-level lamp for the DEF, an emission malfunction lamp, a warning lamp, a DEF quality lamp, and the application stop lamp.The DEF level gauge will only give an accurate reading with the application on level ground.
Illustration 1 g03069862
(1) DEF Level gauge
(A) Low-level warning lamp
Illustration 2 g02852336
Emission malfunction lamp
Warning Indicator Lamps
The warning indicator lamps can function in three different modes.
On solid
Slow flash (once a second)
Fast flash (twice a second)Warning Levels
Any warning should be investigated immediately, contact your Cat dealer. The system is equipped with an override option. Once the override option has been used and the fault still exist, the engine will be locked in de-rate at low idle only.Override Option
The key switch can be cycled in order to give emergency power for 30 minutes.
Turn on key switch for a minimum 5 seconds to a maximum of 15 seconds
Turn off key switch for a minimum 5 seconds to a maximum of 15 seconds
Turn on key switch for a minimum 5 seconds to a maximum of 15 seconds, then crank engine in order to start.Inducement for low-level DEF
When low-level DEF inducement is active there is no override option to cycle the key switch.Before engine operation, ensure that the DEF tank is full. Also, ensure that there is an adequate supply of DEF in order to refill the DEF tank.
Table 1
DEF in Tank Level
Warning Indicator Stop Indicator DEF Low Level Indicator Emission Malfunction Indicator DEF in Tank Level Engine Power Time Comment Action
OFF OFF OFF OFF - Full Power - Normal Operation None
OFF OFF On Solid OFF Less than 20 Percent Full Power - Low DEF Indicator Active Stop Engine and Fill DEF Tank
ON Solid OFF ON Solid ON Solid Less than Ten Percent Full Power - Level 1 Indicators Active
ON Flashing Slowly OFF On Solid ON Flashing Slowly Less than Five Percent Engine will Start to be Derated Derate Timer Starts. A Level 2 Inducement is Active
ON Flashing Fast ON Solid ON Flashing Fast ON Flashing Fast Empty Tank Derate to engine Power Start of 30 Minute Timer A Level 3 nducement is Active
ON Flashing Fast ON Solid ON Flashing Fast ON Flashing Fast Engine will Only Operate at Low Idle. A Level 3 Inducement is Active
Table 2
Inducement for Poor DEF Quality
Warning Indicator Stop Indicator DEF Quality Indicator Emission Malfunction Indicator Engine Power Time Comment Action
OFF OFF OFF OFF Full Power - Normal Operation None
On Solid OFF On Solid On Solid Full Power Start of 50 Minute Timer DEF Quality Out of Range Level 1 Inducement is Active Stop Engine and Check DEF Quality.
Refer to Systems Operation Testing and Adjusting, "Diesel Exhaust fluid Quality - Test" for More Information.
ON Flashing Slowly OFF ON Solid ON Flashing Slowly Start of Engine Derate Start of 40 Minute Derate Ramp A Level 2 Inducement is Active
ON Flashing Fast ON Solid ON Solid ON Flashing Fast Full Engine Derate.
Low Idle (RPM) Only At 210 Minutes A Level 3 Inducement is Active SCR System Inducements
Table 3
SCR System Inducements
Warning Indicator Stop Indicator Emission Malfunction Indicator Engine Power Time Comment Action
OFF OFF OFF Full Power - Normal Operation None
ON Solid or Slow Flashing (1) OFF ON Solid Start of Engine Power Derate Timer Starts, 240 Minutes Before Full Derate A Level 1 Inducement is Active Contact your Cat dealer .
If a Code has been Activated Provide this Information to Your Dealer.
ON Flashing Slowly OFF ON Flashing Slowly Derate to Engine Power and Speed A Level 2 Inducement is Active