09404-06411 Suzuki Clamp

Table 2
Associated Codes
J1939 Code CDL Code Troubleshooting Procedure
3031-1 N/A Troubleshooting, "DEF Tank Temperature Is Low"
3031-17 N/A Troubleshooting, "DEF Tank Temperature Is Low"
3031-18 N/A Troubleshooting, "DEF Tank Temperature Is Low"
4334-3 3090-3 Troubleshooting, "Sensor Signal (Analog, Active) - Test"
4334-4 3090-4 Troubleshooting, "Sensor Signal (Analog, Active) - Test"
4335-15 E1969 (1) Troubleshooting, "Air Assist Pressure Is High"
4335-17 E964 (1) Troubleshooting, "Air Assist Pressure Is Low"
4335-18 E964 (2) Troubleshooting, "Air Assist Pressure Is Low"
4335-3 3092-3 Troubleshooting, "Sensor Signal (Analog, Active) - Test"
4335-4 3094-4 Troubleshooting, "Sensor Signal (Analog, Active) - Test"
4376-5 3862-5 Troubleshooting, "Solenoid Valve - Test"
4376-6 3862-6 Troubleshooting, "Solenoid Valve - Test"
6875-3 3090-3 Troubleshooting, "Sensor Signal (Analog, Active) - Test"
6875-4 3090-4 Troubleshooting, "Sensor Signal (Analog, Active) - Test"
Illustration 1 g03222281
Diesel Exhaust Fluid (DEF) dosing control cabinet components
Valves are shown in a static state
(1) Dosing control cabinet
(2) DEF line to injector at CEM
(3) Air line to injector at CEM
(4) Compressed air source (customer supplied)
(5) DEF source (customer supplied)
(6) DEF pressure sensor
(7) Air assist pressure sensor
(8) Air pressure regulator
(9) Air assist valve (solenoid)
(10) DEF buffer tank return valve (solenoid)
(11) DEF buffer tank return valve (pneumatic)
(12) DEF buffer tank fill valve (solenoid)
(13) DEF buffer tank fill valve (pneumatic)
(14) DEF level sensor
(15) DEF buffer tank
(16) DEF pump
Table 3
Troubleshooting Test Steps Values Results
1. Check for Diagnostic Trouble Codes
A. Turn the breaker to the ON position.
B. Establish communication between Cat ET and the ECM. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
C. Determine if a code is active or logged.
Codes
Result: An associated code is present.
Proceed to the appropriate troubleshooting procedure.
Result: An E931, 4334-17, or 6875-17 code is present.
Proceed to Test Step 2.
2. Check the DEF Pressure Sensor
A. Turn the breaker to the ON position.
B. Connect Cat ET.
D. Monitor the "Aftertreatment #1 DEF Dosing Pressure" in the status screen using Cat ET.
Sensor
Result: The acceptable range of pressure is 0 20 kPa (0 3 psi).
Proceed to Test Step 3.
Result: The recorded pressure is NOT in range.
Repair: Replace the DEF pressure sensor.
Proceed to Test Step 10.
3. Inspect for DEF and Air Leaks
A. Turn the breaker to the OFF position.
B. Inspect the DEF lines between the remote DEF supply and the dosing cabinet.
C. Inspect the lines and manifold inside the dosing cabinet.
D. Inspect the DEF lines between the dosing cabinet and the DEF injector.
E. Inspect the air lines for signs of leakage and ensure that lines are connected.
DEF Leaks
Result: There were no DEF or air leaks.
Proceed to Test Step 4.
Result: There were DEF or air leaks.
Repair: Repair or replace the failed components.
Proceed to Test Step 10.
4. Check for Power at the DEF Pump
A. Turn the power supply ON to the dosing cabinet.
B. Measure the voltage supply to the DEF pump at the circuit breaker.
120 VAC
Result: There was 120 VAC at the circuit breaker.
Proceed to Test step 5.
Result: There was NOT 120 VAC at the circuit breaker.
There is a problem with the power supply to the dosing cabinet. Refer to the appropriate OEM wiring diagram to determine root cause.
5. Test the DEF Lines
A. Turn the breaker to the ON position.
B. Connect Cat ET.
C. Use Cat ET to activate the following overrides:
- Aftertreatment #1 Dosing Air Assist Valve Command Override
D. Monitor Cat ET and record the "Aftertreatment #1 DEF Dosing Pressure".
DEF Pressure
Result: The DEF pressure is reading less than 62 kPa (9 psi).
Proceed to Test Step 6.
Result: The DEF pressure reading is between 62 kPa (9 psi) - 255 kPa (37 psi).
Proceed to Test Step 7.
Result: The DEF pressure is reading greater than 255 kPa (37 psi).
Repair: Replace the DEF injector.
Proceed to Test Step 10.
6. Inspect the DEF Pressure Line
A. Turn the breaker to the OFF position.
B. Disconnect the DEF pressure line from the dosing cabinet.
C. Disconnect the DEF pressure line from the DEF injector.
D. Pour warm water through the DEF pressure line and verify that the lines are not blocked.
DEF Line
Result: The DEF pressure line is blocked.
Repair: Replace the DEF pressure line.
Proceed to Test Step 10.
Result: The DEF pressure line is NOT blocked.
Proceed to Test Step 10.
7. Test the DEF Return Valves
A. Turn the breaker to the ON position.
B. Connect Cat ET.
C. Use Cat ET to activate the following overrides:
- Aftertreatment #1 Dosing Air Assist Valve Command Override
- Aftertreatment #1 DEF Return Valve Override
D. Monitor the "Aftertreatment #1 DEF Dosing Pressure" in the override screen using Cat ET.
DEF Line
Result: The "DEF Pressure" is less than 62 kPa (9 psi) after 30 seconds.
The DEF injector is partially plugged.
Repair: Replace the DEF injector.
Proceed to Test Step 10.
Result: The "DEF Pressure" is greater than 62 kPa (9 psi) after 30 seconds.
Proceed to Test Step 8.
8. Check the Electric DEF Return Valve
A. Turn the breaker to the OFF position.
B. Disconnect the air line at the pneumatic DEF return valve.
C. Turn the breaker to the ON position.
D. Connect Cat ET.
E. Use Cat ET to activate the following overrides:
- Aftertreatment #1 Dosing Air Assist Valve Command Override
F. Physically check