5005963 JOHNSON Service Manual - French

Table 1
Diagnostic Trouble Codes for the DPF Regeneration Switch    
CDL Code     Description     Notes    
3183-2     DPF Regeneration Force Switch : Erratic, Intermittent, or Incorrect     The Electronic Control Module (ECM) detects the following conditions:
An active "Force" signal has been present for at least 60 seconds.    
3184-2     DPF Regeneration Inhibit Switch : Erratic, Intermittent, or Incorrect     The Electronic Control Module (ECM) detects the following conditions:
An active "Inhibit" signal has been present for at least 60 seconds.    The DPF regeneration switch is a 3-position rocker switch. When the switch is held in the FORCE position (up) for 2 seconds, a DPF regeneration is initiated. When the switch is held in the INHIBIT position (down) for 2 seconds, DPF regeneration disabled. The switch returns to the off (center) position when released. If the ECM detects a FORCE or INHIBIT signal for more than 60 seconds, a diagnostic code is generated.
Illustration 1 g03389343
Schematic for the DPF regeneration switch
Illustration 2 g03389375
Ground level shutdown switch and connector (1) Force regeneration (2) Switch return (3) Inhibit regeneration
Illustration 3 g03389414
Pin locations on the P1 connector for the DPF regeneration switch. (18) Switch return (49) Force regeneration (58) Inhibit regenerationTest Step 1. Inspect the Electrical Connectors and the Wiring
Remove the electrical power from the ECM.
Thoroughly inspect the J1/P1 ECM connectors and the connectors for the DPF regeneration switch. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Perform a 45 N (10 lb) pull test on each of the wires for the DPF regeneration switch.
Check the screw for the ECM connector for the correct torque of 6 N m (53 lb in).
Check the harness and the wiring for abrasion and for pinch points from the switch back to the ECM.Expected Result:All of the connectors, pins, and sockets are correctly coupled and/or inserted. The harness and wiring are free of corrosion, abrasion, and pinch points.Results:
OK - The harness and the connectors appear to be OK. Proceed to Test Step 2.
Not OK - There is a fault in the connectors and/or wiring.Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. Ensure that all of the seals are properly in place and ensure that the connectors are correctly coupled.If necessary, use the electronic service tool to perform a "Wiggle Test".Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOPTest Step 2. Check for Active Diagnostic Codes
Connect the electronic service tool to the diagnostic connector.
Restore the electrical power to the ECM.
Wait at least 90 seconds so that any codes may become active.
Remove the electrical power from the ECM.Expected Result:A diagnostic code is not active.Results:
OK - The code does not become active.Repair: The switch is operating normally. There may be an intermittent fault in the wiring harness or in a connector. Check the wiring harness and the connectors for an intermittent electrical fault. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - A diagnostic code is active. Proceed to Test Step 3.Test Step 3. Check the Resistance of the Switch Circuit at the ECM Connector
Disconnect the P1 connector from the engine ECM.Note: Wiggle the harnesses during the following measurements in order to detect any intermittent faults.
Measure the resistance between P1:49 and P1:18. The correct resistance measurement indicates an open circuit.
Measure the resistance between P1:58 and P1:18. The correct resistance measurement indicates an open circuit.
Hold the DPF regeneration switch in the FORCE position.
Measure the resistance between P1:49 and P1:18. The correct resistance measurement indicates a closed circuit.
Measure the resistance between P1:58 and P1:18. The correct resistance measurement indicates an open circuit.
Hold the DPF regeneration switch in the INHIBIT position.
Measure the resistance between P1:49 and P1:18. The correct resistance measurement indicates an open circuit.
Measure the resistance between P1:58 and P1:18. The correct resistance measurement indicates a closed circuit.
Connect the P1 connector to the engine ECM.Expected Result:The resistance measurements are within the specifications.Results:
OK - All of the resistance measurements are within the specifications.Repair: Perform the following procedure:
Restore the electrical power to the ECM.
Use the electronic service tool to check for the active code again. Also, wiggle the switch harness from the switch to the ECM in order to reveal an intermittent fault.
If the code does not recur, the fault is resolved. The original fault was probably caused by a poor electrical connection.
If the code recurs, the ECM is not detecting the switch inputs correctly. Perform the following procedure:
Make sure that the latest flash file for the application is installed in the ECM. Refer to Troubleshooting, "Flash Programming".
Contact the Technical Communicator at a Cat dealer.Note: This consultation can greatly reduce the repair time.
If the Technical Communicator recommends the use of a test ECM, install a test ECM. Refer to Troubleshooting, "Replacing the ECM".
Use the electronic service tool to recheck the system for active diagnostic codes.
If the fault is eliminated with the test ECM, reconnect the suspect ECM.
If the fault returns with the suspect ECM, replace the ECM.
Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOP
Not OK - At least one of the resistance measurements is not within specifications. There is a fault in the switch or in a harness. Proceed to Test Step 4.Test Step 4. Check the Operation of the DPF Regeneration Switch
Disconnect the connector on the DPF regeneration switch.
Measure the resistance between terminal 1 and terminal 2. The correct resistance measurement indicates an open circuit.
Measure the resistance between terminal 3 and terminal 2. The correct resistance measurement indicates an open circuit.
Hold the DPF regeneration switch in the FORCE position.
Measure the resistance between terminal 1 and terminal 2. The correct resistance measurement indicates a closed circuit.
Measure the resistance between terminal 3 and terminal 2. The correct resistance measurement indicates an open circuit.
Hold the DPF regeneration switch in the INHIBIT position.
Measure the resistance between terminal 1 and terminal 2. The correct resista