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Note: Troubleshoot any electrical diagnostic codes associated with the DEF header or CAN C data link before performing the procedure detailed below.Complete the procedure in the order in which the steps are listed.
Table 2
Troubleshooting Test Steps Values Results
1. Check that the latest available software is installed and there are no applicable Technical Information Bulletins or Special Instruction documentation released
A. Ensure that the latest software is installed on the engine ECM.
B. Ensure that the latest software is installed on the Dosing Control Unit (DCU)
If necessary, refer to Troubleshooting, "ECM Software - Install" for the correct procedure.
C. Ensure all Technical Information Bulletins and/or Special Instruction documented for the issue and/or product are reviewed and followed.
Software and Publications
Result: The latest software is not installed.
Repair: Install the latest engine ECM software and then install the latest DCU software. If necessary, refer to Troubleshooting, "ECM Software - Install" for the correct procedure.
Start the engine and wait for 2 minutes.
If the fault is cleared, return the engine to service.
If the fault is still present, proceed to Test Step 2.
Result: Applicable Technical Information Bulletin/Special Instruction publication is available.
Repair: Review and follow instructions provided in the available publication.
Result: The latest software is installed.
Proceed to Test Step 2.
2. Check the DEF Fluid Level
A. Turn the keyswitch to the ON position. Do not start the engine.
B. Check the current position of the DEF gauge.
Note: The gauge may take up to 30 seconds to show the correct DEF level.
C. Turn the keyswitch to the OFF position.
D. Clean dirt and debris from around the cap before removing the cap.
E. Add DEF to the DEF tank.
Note: Only use DEF that meets ISO 22241 quality standards.
F. Turn the keyswitch to the ON position.
G. Check for a change in the gauge position.
Gauge position
Result: The gauge did not move by adding DEF to the tank.
Proceed to Test Step 3.
Repair: The gauge moved by adding DEF to the tank. Turn the keyswitch to the OFF position until the "Wait to Disconnect" lamp switches off to allow the DEF pump to purge, reset the code, and reset the DEF Control Unit (DCU).
Return the unit to service.
3. Check the ECM Software Initializes Correctly
A. Turn the keyswitch to the OFF position for 2 minutes.
B. Turn the keyswitch to the ON position.
C. Check for a change in the DEF gauge position.
Gauge position
Result: The gauge did not move after initializing the ECM.
Repair: Proceed to Test Step 4.
Result: The gauge indicates the correct DEF level.
Return the engine to service.
4. Check the DEF Level Measurement
A. Operate the machine to agitate the DEF in the tank
Gauge position
Result: The gauge did not move.
Repair: Repair the DEF Tank header sensor with the DEF Manifold Sensor Kit. Refer to Disassembly and Assembly, Manifold (DEF Heater) Sensor - Disassemble (Temperature, Level, Quality DEF Manifold Sensor) and Manifold (DEF Heater) Sensor - Assemble (Temperature, Level, Quality DEF Manifold Sensor).
Result: The gauge moved.
Proceed to Test Step 5.
5. Check the DEF Tank Configuration
A. Turn the keyswitch to the ON position.
B. Connect to the electronic service tool.
C. go to the configuration screen.
Check that the "Aftertreatment #1 DEF Tank Configuration" or the "DEF Tank Height Parameters" are correct for the application.
DEF tank configuration
Result: The DEF tank configuration is incorrect.
Repair: Make the necessary corrections and return the engine to service.
For custom tank configurations, contact the Dealer Solutions Network (DSN).
Result: The DEF tank configuration is correct.
Proceed to Test Step 6.
Illustration 1 g03715320
Table 3
Troubleshooting Test Steps Values Results
6. Check the Electrical Connection at the DEF Tank Header
A. Inspect electrical connector (1) to the DEF tank header. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Check for corrosion or loose wires.
Electrical connections
Result: The electrical connectors are free of corrosion and are not loose.
Proceed to Test Step 7.
Result: The electrical connections are corroded and/or loose.
Repair: Make the necessary repairs to the connectors. Turn the keyswitch to the OFF position until the "Wait to Disconnect" lamp switches off to allow the DEF pump to purge, reset the code, and reset the Dosing Control Unit (DCU).
Use the electronic service tool to perform the "Aftertreatment System Functional Test" to ensure that the repair eliminates the fault.
Repeat this procedure from Test Step 1.
7. Inspect the DEF Tank Header
A. Turn the keyswitch to the OFF position.
B. Remove tank header (2) from the DEF tank. Refer to Disassembly and Assembly, "Manifold (DEF Heater) - Remove and Install".
C. Inspect the DEF tank header for damage.
Proper operation of the float
Result: The level sensor was not operating correctly.
Repair: Repair the DEF Tank header sensor with the DEF Manifold Sensor Kit. Refer to Disassembly and Assembly, Manifold (DEF Heater) Sensor - Disassemble (Temperature, Level, Quality DEF Manifold Sensor) and Manifold (DEF Heater) Sensor - Assemble (Temperature, Level, Quality DEF Manifold Sensor).
If the fault is still present, contact the Dealer Solutions Network (DSN).