0586397 JOHNSON RELAY ASSEMBLY, 70 Amp

Required Tooling
The table below contains the tooling that is required to complete this procedure.
Table 2
Required Service Tools
Part Number Description
441-0451 Kit - Test Recommended Actions
Table 3
Troubleshooting Test Steps Values Results
1. Determine the Code.
A. Establish communication between Cat® Electronic Technician (ET) and the Electronic Control Module (ECM).
B. Download the "Warranty Report" from the Aftertreatment ECM before performing any troubleshooting or clearing any diagnostic trouble codes.
C. Determine the diagnostic trouble code that is active.
Diagnostic Code
Result : A E1410 (2) or 4364-2 code is active or logged.
Proceed to Test Step 2.
Result : For all codes other than a E1410 (2) or 4364-2, proceed to Test Step 3.
2. Check the NOx Sensors for Proper Installation.
A. Turn the keyswitch to OFF.
B. Verify that the sensors are located in the correct position.
Note : The "Engine Out NOx" sensor wiring has a black sheath. The "Tailpipe Out NOx" sensor wiring has a gray sheath.
C. If the sensors are installed in the wrong positions, install the sensors in the correct positions. Refer to Special Instruction, REHS8151 for the correct handling procedures.
D. Perform a "Aftertreatment System Functional Test" using Cat ET.
NOx Sensors
Result : The "Aftertreatment System Functional Test" completed successfully.
Return the unit to service.
Result : The "Aftertreatment System Functional Test" did not complete successfully and other codes were logged.
Repair : Troubleshoot the logged codes.
Result : The "Aftertreatment System Functional Test" did not complete successfully and no codes were logged.
Proceed to Test Step 3.
3. Check the DEF Level and Temperature
DEF Level and Quality
Result: The DEF level is above 30% and the DEF tank temperature is below 58° C (136° F).
Proceed to Test Step 4.
Result: The DEF tank level is below 30% or the DEF tank temperature is above 58° C (136° F).
Repair : Refill the DEF tank to above 50% level and ensure that the DEF tank temperature is below 58° C (136° F).
Proceed to Test Step 4.
4. Check the Diesel Exhaust Fluid (DEF) Quality.
A. Measure the DEF quality. Refer to Testing and Adjusting, "Diesel Exhaust Fluid Quality - Test" for the correct procedure.
DEF
Result : The DEF is not contaminated and the concentration is not within the acceptable range.
Repair : Drain the DEF from the tank. Refill the tank with DEF that meets ISO 22241 quality standards.
Proceed to Test Step 16.
Result: The DEF is not contaminated and the concentration is within the acceptable range.
Proceed to Test Step 5.
Result : The DEF is contaminated.
Repair : Contact the DSN for further information.
5. Determine the DEF Quality Sensor Installation Status
A. Use Cat ET to check the status of the configuration parameter "Aftertreatment #1 DEF Quality Sensor Installation Status".
Note: DO NOT change the installation status in Cat ET if the status is "Not Installed".
Parameter
Result : "Aftertreatment #1 DEF Quality Sensor Installation Status" is set to "Installed".
Proceed to Test Step 6.
Result : "Aftertreatment #1 DEF Quality Sensor Installation Status" is set to "Not Installed" or is not listed.
Proceed to Test Step 8.
6. Determine the Diagnostic Code
A. Connect Cat ET
B. Determine the code that is active.
Code
Result : A 3516-15, 3516-16, E1365 (1), or E1365 (2) code is active.
Repair : Replace the DEF tank header assembly.
Result : An E1364 (2), or 3516-18 code is active or logged.
Repair : Replace the DEF tank header assembly.
Repair : Proceed to Test Step 16.
Result : A 3516-11 code is active or logged.
Proceed to Test Step 7.
Result : A E1309 (2) or 4364–18 code is active or logged.
Proceed to Test Step 8.
7. Remove the DEF Tank Header Assembly and Sock Filter from DEF Tank
A. Inspect for debris or obstructions blocking the DEF Quality Sensor optical path.
Debris
Result: Debris or an obstruction was blocking the DEF quality sensor optical path.
Repair: Remove any debris blocking the DEF quality sensor optical path. Replace the sock filter. Reinstall the DEF tank header assembly.
Proceed to Test Step 16.
Result: Debris or obstructions were not blocking the DEF Quality Sensor optical path.
Repair: Replace the DEF tank header assembly.
Proceed to Test Step 16.
8. Inspect All of the DEF Lines for Leaks.
A. Turn the keyswitch to ON. Do not start the engine.
B. Connect to the "Diesel Exhaust Fluid Controller #1 ECM" in Cat ET.
C. Perform the "DEF Dosing System Verification Test" to pressurize the system. Refer to Troubleshooting, "Cat ET Service Features" for more information.
Note: This test can take up to 30 minutes to complete.
D. Visually inspect all DEF lines from the tank to the DEF injector. Look for pinched, damaged, or disconnected lines.
E. Inspect the lines for leakage.
F. Turn the keyswitch to OFF.
DEF Lines
Result : The lines are leaking, damaged, pinched, or disconnected.
Repair : Make the necessary repairs.
Proceed to Test Step 16.
Result : The lines are not leaking, damaged, pinched, or disconnected.
Proceed to Test Step 9.
9. Perform an "Aftertreatment NOx Sensor Functional Test".
A. Start the engine.
B. Connect to the "Engine #1 Aftertreatment Control ECM" using Cat ET.
C. Perform an "Aftertreatment NOx Sensor Functional Test".
Aftertreatment NOx Sensor Functional Test
Result : The test completed successfully.
Proceed to Test Step 10.
Result : The test did not complete successfully. A failed NO