854F Troubleshooting Guide PDF

UENR4504
January 2015
Troubleshooting
854F-E34TA Industrial Engine
JU (Engine)
This document has been printed from SPI2. NOT FOR RESALE
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
UENR4504 3
Table of Contents
Table of Contents DEF Pressure Is High ................... .................. 80

DEF Pressure Is Low................... ................... 82
Troubleshooting Section DEF Tank Level Is Low .................. ................. 86
DEF Tank Temperature Is High............ ........... 88
Electronic Troubleshooting DEF Tank Temperature Is Low ............ ........... 92
Welding Precaution ..................... ..................... 5 ECM Does Not Communicate with Other
System Overview....................... ....................... 5 Modules ............................ ............................ 95
Glossary .............................. ............................. 9 Electronic Service Tool Does Not
Communicate........................ ........................ 95
Electronic Service Tools ................. ................ 12
Engine Cranks but Does Not Start......... ......... 97
Indicator Lamps ....................... ....................... 14
Engine Does Not Crank................ ................ 102
Replacing the ECM..................... .................... 17
Engine Has Early Wear ................ ................ 104
Self-Diagnostics....................... ....................... 18
Engine Has Mechanical Noise (Knock) .... .... 106
Sensors and Electrical Connectors ........ ........ 19
Engine Misfires, Runs Rough or Is Unstable 109
Engine Wiring Information ............... ............... 23
Engine Overspeeds................... ....................112
ECM Harness Connector Terminals ........ ....... 31
Engine Shutdown Occurs Intermittently .... ....112
Service Tool Features................... .................. 31
Engine Speed Does Not Change ......... .........114
Engine Stalls at Low RPM .............. ...............115
Programming Parameters
Engine Top Speed Is Not Obtained ....... ........117
Programming Parameters ............... ............... 34
Engine Vibration Is Excessive ........... ........... 120
Flash Programming .................... .................... 34
Exhaust Has Excessive Black Smoke..... ..... 122
Injector Code - Calibrate................. ................ 34
Exhaust Has Excessive White Smoke .... ..... 125
Mode Switch Setup..................... .................... 35
Exhaust System Contains Oil ............ ........... 128
Throttle Setup ......................... ........................ 37
Fuel Consumption Is Excessive .......... ......... 130
Multiposition Switch Setup............... ............... 39
Fuel Contains Water ................... .................. 133
Fuel Rail Pressure Problem............. ............. 134
Customer Specified Parameters
Fuel Temperature Is High ............... .............. 140
Customer Specified Parameters........... .......... 41
Inlet Air Is Restricted................... .................. 141
Customer Specified Parameters Table ...... ..... 45
Inlet Air Temperature Is High ............ ............ 142
Customer Specified Parameters Worksheet . . 49
Intake Manifold Air Pressure Is High ...... ...... 143
Intake Manifold Air Pressure Is Low ....... ...... 144
System Configuration Parameters
Intake Manifold Air Temperature Is High.... ... 146
System Configuration Parameters......... ......... 53
NOx Conversion Is Low................ ................ 149
NRS Mass Flow Rate Problem........... .......... 151
Symptom Troubleshooting
Oil Consumption Is Excessive ........... ........... 153
Acceleration Is Poor or Throttle Response Is
Oil Contains Coolant................... .................. 155
Poor ............................... ............................... 54
Oil Contains Fuel ..................... ..................... 157
Alternator Is Noisy ..................... ..................... 57
Oil Pressure Is Low.................... ................... 159
Alternator Problem (Charging Problem and/or
Power Is Intermittently Low or Power Cutout Is
Noisy Operation)...................... ..................... 59
Intermittent......................... ......................... 162
Battery Problem....................... ....................... 60
SCR Catalyst Has Incorrect Inlet
Coolant Contains Oil.................... ................... 61
Temperature........................ ........................ 165
Coolant Level Is Low ................... ................... 63
SCR Warning System Problem .......... .......... 166
Coolant Temperature Is High............. ............. 63
Valve Lash Is Excessive ................ ............... 174
Coolant Temperature Is Low.............. ............. 66
Crankcase Breather Ejects Oil ............ ........... 67
Cylinder Is Noisy....................... ...................... 70 Troubleshooting with a Diagnostic Code
DEF Concentration Is Incorrect ........... ........... 71 Diagnostic Trouble Codes .............. .............. 175
DEF Does Not Purge................... ................... 73
DEF Module Does Not Respond .......... .......... 75 Diagnostic Functional Tests
DEF Pressure Does Not Respond......... ......... 76 CAN Data Link - Test .................. .................. 184
DEF Injector - Test .................... .................... 189
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Table of Contents
DEF Line Heater - Test ................. ................ 193

DEF Pump - Test ..................... ..................... 199
DEF Pump Pressure Sensor - Test........ ....... 205
DEF Return Valve - Test ................ ............... 209
DEF Tank Sensor - Test................ ................ 213
ECM Memory - Test ................... ................... 218
Electrical Connector - Inspect............ ........... 221
Electrical Power Supply - Test ........... ........... 224
Glow Plug Starting Aid - Test ............ ............ 228
Idle Validation - Test................... ................... 234
Indicator Lamp - Test .................. .................. 241
Injector Data Incorrect - Test............. ............ 245
Injector Solenoid - Test ................. ................ 248
Mode Selection - Test .................. ................. 255
Motorized Valve - Test ................. ................. 258
NOx Sensor - Test .................... .................... 264
Power Take-Off - Test .................. ................. 268
Relay - Test (Start Relay)............... ............... 273
Relay - Test (ECM Main Relay) .......... .......... 278
Relay - Test (SCR Relay)............... ............... 282
Sensor (Data Link Type) - Test (Ammonia
Sensor) ............................ ........................... 288
Sensor Supply - Test................... .................. 292
Sensor Signal (Analog, Active) - Test (Exhaust
Gas Pressure Sensor) ................ ................ 297
Sensor Signal (Analog, Active) - Test ...... ..... 303
Sensor Signal (Analog, Passive) - Test .... .... 309
Solenoid Valve - Test (Coolant Diverter
Valve)............................. ............................. 316
Solenoid Valve - Test .................. .................. 319
Speed Control (Analog) - Test ........... ........... 326
Speed/Timing - Test................... ................... 331
Switch Circuits - Test (Engine Oil Pressure
Switch) ............................ ............................ 339
Switch Circuits - Test (Throttle Switch) ..... .... 345
Switch Circuits - Test (Air Filter Restriction
Switch) ............................ ............................ 348
Valve Position - Test ................... .................. 353
Water in Fuel - Test.................... ................... 359
Index Section
Index............................... .............................. 363
UENR4504 5
Electronic Troubleshooting
Troubleshooting Section
i05980253
Welding Precaution
Correct welding procedures are necessary in order to

avoid damage to the Electronic Control Module
(ECM) , to sensors, and to associated components.
Components for the driven equipment should also be
considered. When possible, remove the component
that requires welding. When welding on an
application that is equipped with an electronically
controlled engine and removal of the component is
not possible, the following procedure must be Illustration 1 g01143634
followed. This procedure minimizes the risk to the Service welding guide (typical diagram)
electronic components.
1. Stop the engine. Remove the electrical power from 5. When possible, connect the ground clamp for the
the ECM. welding equipment directly to the engine
component that will be welded. Place the clamp as
2. Ensure that the fuel supply to the engine is turned close as possible to the weld. Close positioning
off. reduces the risk of welding current damage to the
engine bearings, to the electrical components, and
3. Disconnect the negative battery cable from the
to other components.
battery. If a battery disconnect switch is installed,
open the switch. 6. Protect the wiring harnesses from welding debris
and/or from welding spatter.
4. Disconnect all electronic components from the
wiring harnesses. Include the following 7. Use standard welding procedures to weld the
components: materials together.
• Electronic components for the driven equipment
i05949712
• ECM
System Overview
• Sensors
• Electronically controlled valves The engine has an electronic control system. The
system also monitors the engine aftertreatment and
• Relays the Exhaust Gas Recirculation (EGR) systems.
• Electronic control units The control system consists of the following
components:
NOTICE • Electronic Control Module (ECM)
Do not use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for • Software (flash file)
grounding the welder.
• Wiring
• Sensors
• Actuators
6 UENR4504
The following information provides a general

description of the control system. Refer to Systems
Operation, Testing, and Adjusting for detailed
information about the control system.
Electronic Control Circuit Diagram
Illustration 2 g03697844
Electronic control circuit diagram for the 854F-E34TA engine
UENR4504 7
Block Diagram
Block diagram for the 854F-E34TA engine
(1) EGR valve (10) Engine exhaust gas temperature sensor (19) Fuel transfer pump
(2) Air cleaner (11) Primary speed/timing sensor (20) Primary fuel filter with water-in-fuel
(3) Air inlet temperature sensor (12) Secondary speed/timing sensor sensor
(4) EGR cooler (13) Fuel injectors (21) Intake manifold air temperature/
(5) Turbocharger (14) High-pressure fuel pump pressure sensor
(6) Engine intake throttle valve (15) Fuel rail pressure sensor (22) Secondary fuel filter with fuel
(7) Wastegate regulator (16) Oil pressure switch temperature sensor
(8) Air-to-air aftercooler (17) Coolant temperature sensor (23) Fuel tank
(9) Engine exhaust gas pressure sensor (18) Engine
Block diagram for the aftertreatment
(24) Diesel Exhaust Fluid (DEF) temperature (28) DEF tank header unit
sensor (29) DEF tank
(25) DEF level sensor (30) DEF pump pressure sensor
(26) DEF quality sensor (31) DEF pump filter
(27) Coolant diverter valve (32) DEF pump module
8 UENR4504
(33) DEF injector (37) DEF mixer (41) SCR outlet temperature sensor
(34) Engine out NOx sensor (38) Selective Catalytic Reduction (SCR) (42) Tailpipe out NOx sensor
(35) Diesel Oxidation Catalyst (DOC) inlet inlet temperature sensor (43) Ammonia sensor
temperature sensor (39) SCR catalyst
(36) DOC (40) Ammonia Oxidizing (AMOX) catalyst
System Operation • Coolant temperature sensor

• Intake manifold air temperature sensor
Engine Governor
• Intake manifold pressure sensor
The ECM governs the engine. The ECM determines
the timing, the injection pressure, and the amount of • NOx sensors
fuel that is delivered to each cylinder. These factors
are based on the actual conditions and on the desired The ECM adjusts timing for optimum engine
conditions at any given time during starting and performance and for economic fuel usage. Actual
operation. timing and desired timing cannot be viewed with the
electronic service tool. The ECM determines the
The governor uses the throttle position sensor to location of top center of the number one cylinder from
determine the desired engine speed. The governor the signals that are provided by the engine speed/
compares the desired engine speed to the actual timing sensors. The ECM determines when injection
engine speed. The actual engine speed is determined should occur relative to the top center position. The
through interpretation of the signals that are received ECM then provides the signal to the injector at the
by the ECM from the engine speed/timing sensors. If desired time.
the desired engine speed is greater than the actual
engine speed, the governor injects more fuel in order
to increase engine speed. Fuel Injection
The ECM sends a high voltage signal to the injector
solenoids in order to energize the solenoids. By
controlling the timing and the duration of the high
voltage signal, the ECM can control the following
aspects of injection:
• Injection timing
• Fuel delivery
Customer Parameters and Engine Speed

Governing
A unique feature with electronic engines is customer
specified parameters. These parameters allow the
owner of the machine to fine-tune the ECM for engine
operation. Fine-tuning the ECM allows the machine
owner to accommodate the typical usage of the
machine and the power train of the machine.
Many of the customer parameters provide additional
restrictions on the actions that will be performed by
the ECM in response to input from the operator. The
Typical example PTO Top Engine Limit is an engine rpm limit that is
used by the ECM to limit the fuel during operation of
The desired engine speed is typically determined by the PTO. The ECM will not fuel the injectors above
one of the following conditions: this rpm.
• The position of the throttle Some parameters are intended to notify the operator
of potential engine damage (engine monitoring
• The desired engine speed in Power Take-Off parameters). Some parameters enhance fuel
(PTO) economy (machine speed, engine speed limit, and
idle shutdown). Other parameters are used to
Timing Considerations enhance the engine installation into the machine.
Other parameters are used to provide any engine
operating information to the owner of the machine.
Once the governor has determined the amount of fuel
that is required, the governor must determine the
timing of the fuel injection. Fuel injection timing is
determined by the ECM after considering input from
the following components:
UENR4504 9
Other ECM Functions for buses that are used for communication with other
microprocessor-based devices.
Performance
Code – Refer to “Diagnostic Trouble Code” .
The ECM can also provide enhanced control of the
engine for machine functions. Refer to Communication Adapter Tool – The communication
Troubleshooting, “Configuration Parameters” for adapter provides a communication link between the
supplemental information about the systems that can ECM and the electronic service tool.
be monitored by the ECM in order to provide
enhanced machine performance, fuel economy, and Coolant Temperature Sensor – The coolant
convenience for the operator. temperature sensor detects the engine coolant
temperature for all normal operating conditions and
for engine monitoring.
Programmable Parameters
Data Link – The data link is a serial communication
Certain parameters that affect engine operation may bus that is used for communication with other devices
be changed with the electronic service tool. The such as the electronic service tool.
parameters are stored in the ECM.
Derate – Certain engine conditions will generate
Customer parameters are variable. Customer event codes. Also, engine may be derated. The map
parameters can affect the following characteristics of for the engine derate is programmed into the ECM
the engine within the limits that are set by the factory, software. The type of derate can be one or more of
by the monitoring system, and by PTO operation: three types: reduction of rated power, reduction of
rated engine speed and reduction of rated machine
• Rpm ratings speed for OEM products.
Some of the parameters may affect engine operation Desired Engine Speed – The desired engine speed
in an unusual way. An operator might not expect this is input to the electronic governor within the ECM.
type of effect. Without adequate training, these The electronic governor uses the throttle position
parameters may lead to power complaints or sensor signal, the engine speed/timing sensor, and
performance complaints even though the other sensors in order to determine the desired
performance of the engine is to the specification. engine speed.
Refer to Troubleshooting, “Configuration Parameters” Diagnostic Trouble Code – A diagnostic trouble

for additional information on this subject. code is sometimes referred to as a fault code. These
codes indicate an electronic system malfunction.
i05857062
Diagnostic Lamp – The diagnostic lamp is also
called the warning lamp. The diagnostic lamp is used
to warn the operator of the presence of an active
Glossary diagnostic code. The lamp may not be included in all
applications.
Active Diagnostic Code – An active diagnostic code Diesel Exhaust Fluid (DEF) – DEF is a mixture of
alerts the operator or the service technician that an urea and water that is injected into the exhaust
electronic system malfunction is currently present. stream. The heat in the exhaust gas releases the
Refer to the term “Diagnostic Code” in this glossary. ammonia in the DEF. The ammonia reacts with the
oxides of nitrogen (NOx) in the SCR filter to produce
Aftertreatment – Aftertreatment is a system that is nitrogen and water vapor.
used to remove pollutants from exhaust gases. The Diesel Oxidation Catalyst (DOC) – The DOC is a
system consists of a Diesel Oxidation Catalyst (DOC) device in the exhaust system that oxidizes certain
and a Selective Catalytic Reduction (SCR) system. elements in the exhaust gases. These elements can
Alternating Current (AC) – Alternating current is an include carbon monoxide (CO), hydrocarbons and the
electric current that reverses direction at a regular soluble organic fractions (SOF) of particulate matter.
interval that is reoccurring. Digital Sensor Return – The common line (ground)
Ammonia Oxidizing (AMOX) catalyst – The AMOX from the ECM is used as ground for the digital
catalyst removes any residual ammonia from the sensors.
exhaust gas stream after completion of the Selective Digital Sensors – Digital sensors produce a pulse
Catalytic Reduction (SCR) process. width modulated signal. Digital sensors are supplied
Before Top Center (BTC) – BTC is the 180 degrees with power from the ECM.
of crankshaft rotation before the piston reaches the Digital Sensor Supply – The power supply for the
top center position in the normal direction of rotation. digital sensors is provided by the ECM.
Bypass Circuit – A bypass circuit is a circuit that is Direct Current (DC) – Direct current is the type of
used as a substitute circuit for an existing circuit. A current that flows consistently in only one direction.
bypass circuit is typically used as a test circuit.
CAN Data Links (see also J1939 CAN Data Link) –
The CAN Data Links are serial communications
10 UENR4504
DT, DT Connector, or Deutsch DT – This design is 3 – The voltage is above normal or the voltage is
a type of connector that is used on this engine. The shorted high.
connectors are manufactured by Deutsch .
4 – The voltage is below normal or the voltage is
Duty Cycle – Refer to “Pulse Width Modulation” . shorted low.
Electronic Engine Control – The electronic engine 5 – The current is below normal or the circuit is open.
control is a complete electronic system. The
electronic engine control monitors the engine 6 – The current is above normal or the circuit is
operation under all conditions. The electronic engine grounded.
control also controls the engine operation under all 7 – The mechanical system is not responding
conditions. properly.
Electronic Control Module (ECM) – The ECM is the 8 – There is an abnormal frequency, an abnormal
control computer of the engine. The ECM provides pulse width, or an abnormal time period.
power to the electronics. The ECM monitors data that
is input from the sensors on the engine and the 9 – There has been an abnormal update.
aftertreatment. The ECM acts as a governor in order
to control the speed and the power of the engine. 10 – There is an abnormal rate of change.
Electronic Service Tool – The electronic service tool 11 – The failure mode is not identifiable.
allows a computer (PC) to communicate with the
ECM. 12 – The device or the component is damaged.
Engine Monitoring – Engine Monitoring is the part of 13 – The device requires calibration.
the electronic engine control that monitors the
sensors. Engine monitoring also warns the operator 14 – There is a special instruction for the device.
of detected problems. 15 – The signal from the device is high (least severe).
Engine Oil Pressure Switch – The oil pressure 16 – The signal from the device is high (moderate
switch detects engine oil pressure. The oil pressure severity).
switch is used for engine protection. If insufficient oil
pressure is detected during engine operation, an 17 – The signal from the device is low (least severe).
event for low oil pressure will be raised.
18 – The signal from the device is low (moderate
Engine Speed/Timing Sensor – An engine speed/ severity).
timing sensor is a hall effect switch that provides a
digital signal to the ECM. The ECM interprets this 19 – There is an error in the data from the device.
signal as the crankshaft position and the engine
speed. Two sensors are used to provide the speed 31 – No FMI description required
and timing signals to the ECM. The primary sensor is
associated with the crankshaft and the secondary Flash File – This file is software that is inside the
sensor is associated with the camshaft. ECM. The file contains all the instructions (software)
for the ECM and the file contains the performance
Event Code – An event code may be activated in maps for a specific engine. The file may be
order to indicate an abnormal engine operating reprogrammed through flash programming.
condition. These codes usually indicate a mechanical
problem instead of an electrical system problem. Flash Programming – Flash programming is the
method of programming or updating an ECM with an
Exhaust Gas Recirculation – The Exhaust Gas electronic service tool over the data link instead of
Recirculation (EGR) system recycles a portion of the replacing components.
exhaust gases back into the inlet air. The recirculation
reduces the oxides of nitrogen (NOx) in the exhaust Fuel Pump – See “High Pressure Fuel Pump” .
gases. The recycled exhaust gas passes through a
cooler before being introduced into the inlet air. Fuel Rail – This item is sometimes referred to as the
High Pressure Fuel Rail. The fuel rail supplies fuel to
Failure Mode Identifier (FMI) – This identifier the electronic unit injectors. The high-pressure fuel
indicates the type of failure that is associated with the pump and the fuel rail pressure sensor work with the
component. The FMI has been adopted from the SAE ECM to maintain the desired fuel pressure in the fuel
practice of J1587 diagnostics. The FMI follows the rail. This pressure is determined by calibration of the
parameter identifier (PID) in the descriptions of the engine in order to enable the engine to meet
fault code. The descriptions of the FMIs are in the emissions and performance requirements.
following list.
Fuel Rail Pressure Sensor – The fuel rail pressure
0 – The data is valid but the data is above the normal sensor sends a signal to the ECM that is dependent
operational range. on the pressure of the fuel in the fuel rail.
1 – The data is valid but the data is below the normal Glow Plug – The glow plug is a starting aid for cold
operational range. conditions. One glow plug is installed in each
combustion chamber in order to improve the ability of
2 – The data is erratic, intermittent, or incorrect.
the engine to start. The ECM uses information from
UENR4504 11
the engine sensors to determine when the glow plug exists, the signal or the supply voltage can no longer
control unit must provide power to each glow plug. reach the intended destination.
Each of the glow plugs then provides a hot surface in
the combustion chamber in order to vaporize the Oxides of Nitrogen (NOx) – NOx is a component of
mixture of air and fuel. The vaporization improves the exhaust gases that are produced by the
ignition during the compression stroke of the cylinder. combustion process. NOx is reduced by the EGR
system and is further reduced by the SCR component
Glow Plug Control Unit – The Glow plug Control of the aftertreatment system.
Unit (GCU) is controlled by the ECM in order to
provide high current to the glow plugs. The Parameter – A parameter is a value or a limit that is
programmable. A parameter helps determine specific
Harness – The harness is the bundle of wiring (loom) characteristics or behaviors of the engine.
that connects all components of the electronic
system. Personality Module – See “Flash File” .
Hertz (Hz) – Hertz is the measure of electrical Post Run – The time duration between the keyswitch
frequency in cycles per second. being turned to the OFF position and the main relay
switching off the power to the ECM (approximately 30
High Pressure Fuel Pump – This device supplies seconds).
fuel under pressure to the fuel rail (high-pressure fuel
rail). Power Cycling – Power cycling refers to the action of
cycling the keyswitch from any position to the OFF
High Pressure Fuel Rail – See “Fuel Rail” . position, and to the START/RUN position.
Injector Trim Codes – Injector trim codes are codes Pressure Relief Valve (PRV) – The PRV is a valve in
that contain seven characters. The codes are the fuel rail that prevents excessive pressure. The
supplied with new injectors. The code is input through PRV will reduce the pressure to a safe level that will
the electronic service tool into the ECM. The injector limit engine operation but the reduced pressure will
trim codes compensate for variances in not stop the engine.
manufacturing of the electronic unit injector and for
the life of the electronic unit injector. Primary Speed/Timing Sensor – This sensor
determines the position of the crankshaft during
Intake Manifold Air Temperature Sensor – The engine operation. If the primary speed/timing sensor
intake manifold air temperature sensor detects the air fails during engine operation, the secondary speed/
temperature in the intake manifold. The ECM timing sensor is used to provide the signal.
monitors the air temperature and other data in the
intake manifold in order to adjust injection timing and Pulse Width Modulation (PWM) – The PWM is a
other performance functions. signal that consists of pulses that are of variable
width. These pulses occur at fixed intervals. The ratio
Intake Manifold Pressure Sensor – The Intake of “TIME ON” versus “TIME OFF” can be varied.
Manifold Pressure Sensor measures the pressure in This ratio is also referred to as a duty cycle.
the intake manifold. The pressure in the intake
manifold may be different to the pressure outside the
engine (atmospheric pressure). The difference in
pressure may be caused by an increase in air
pressure by a turbocharger.
Integrated Electronic Controls – The engine is
designed with the electronic controls as a necessary
part of the system. The engine will not operate
without the electronic controls.
J1939 CAN Data Links – These data links are SAE
standard diagnostic communications data links that
are used to communicate between the ECM and
other electronic devices.
Logged Diagnostic Codes – Logged diagnostic
codes are codes which are stored in the memory.
These codes are an indicator of possible causes for
intermittent problems. Refer to the term “Diagnostic
Trouble Codes” for more information.
OEM – OEM is an abbreviation for the Original
Equipment Manufacturer. The OEM is the
manufacturer of the machine or the vehicle that uses
the engine.
Open Circuit – An open circuit is a condition that is
caused by an open switch, or by an electrical wire or Reference Voltage – Reference voltage is a
a connection that is broken. When this condition regulated voltage that is supplied by the ECM to a
12 UENR4504
sensor. The reference voltage is used by the sensor

to generate a signal voltage. Wait To Start Lamp – This lamp is included in the
cold starting aid circuit in order to indicate when the
Relay – A relay is an electromechanical switch. A wait to start period is active. The lamp will go off when
flow of electricity in one circuit is used to control the the engine is ready to be started. The glow plugs may
flow of electricity in another circuit. A small current or not have deactivated.
voltage is applied to a relay in order to switch a much
larger current or voltage. Warning Lamp – The warning lamp is used to warn
the operator of the presence of an active diagnostic
Secondary Speed/Timing Sensor – This sensor code.
determines the position of the camshaft during engine
operation. If the primary speed/timing sensor fails Wastegate – The wastegate is a device in a
during engine operation, the secondary speed/timing turbocharged engine that controls the maximum
sensor is used to provide the signal. boost pressure that is provided to the inlet manifold.
Selective Catalytic Reduction (SCR) – SCR is a Wastegate Regulator – The wastegate regulator
process for reducing the oxides of nitrogen (NOx) in controls the pressure in the intake manifold to a value
the exhaust gases. Ammonia is introduced into the that is determined by the ECM. The wastegate
exhaust and reacts with the exhaust gases in the regulator provides the interface between the ECM
SCR catalyst to convert the NOx into nitrogen and and the mechanical system.
water vapor.
Sensor – A sensor is a device that is used to detect i05949762
the current value of pressure or temperature, or
mechanical movement. The information that is
detected is converted into an electrical signal. Electronic Service Tools
Short Circuit – A short circuit is a condition that has
an electrical circuit that is inadvertently connected to
an undesirable point. An example of a short circuit is Perkins electronic service tools are designed to help
a wire which rubs against a vehicle frame and this the service technician:
rubbing eventually wears off the wire insulation.
Electrical contact with the frame is made and results • Retrieve diagnostic codes
in a short circuit.
• Diagnose electrical problems
Signal – The signal is a voltage or a waveform that is
used in order to transmit information typically from a • Read parameters
sensor to the ECM.
• Program parameters
Supply Voltage – The supply voltage is a continuous
voltage that is supplied to a component. The power • Install injector trim codes
may be generated by the ECM or the power may be
battery voltage that is supplied by the engine wiring. Required Service Tools
Suspect Parameter Number (SPN) – The SPN is a Table 1
J1939 number that identifies the specific component
of the electronic control system that has experienced Required Service Tools
a fault. Part Number Description
Throttle Position – The throttle position is the T400077 Extraction Tool
interpretation by the ECM of the signal from the
throttle position sensor or the throttle switch. T400078 Extraction Tool
Throttle Position Sensor – The throttle position T400079 Extraction Tool

sensor is a sensor that is connected to an accelerator T400080 Extraction Tool
pedal or a hand lever. This sensor sends a signal to
the ECM that is used to calculate desired engine T400081 Extraction Tool
speed. - Suitable Digital Multimeter
Throttle Switch – The throttle switch sends a signal
to the ECM that is used to calculate desired engine
speed. Optional Service Tools
Top Center Position – The top center position refers Table 2 lists the optional service tools that can be
to the crankshaft position when the engine piston used when the engine is serviced.
position is at the highest point of travel. The engine
must be turned in the normal direction of rotation in
order to reach this point.
Total Tattletale – The total tattletale is the total
number of changes to all the parameters that are
stored in the ECM.
UENR4504 13
Table 2 (Table 3, contd)

Part Number Description Service Tools for the Use of the Electronic Service
Tool
U5MK1092 Spoon Probe Kit
MULTIMETER Part Number Description
-(1) Data Subscription for All Engines
- Suitable Digital Pressure Indicator
or or 27610164 TIPSS Adapter Kit (Electronic Service Tool to the
- Engine Pressure Group ECM interface)
or
- Suitable Battery Load Tester 27610401 Perkins CA3 Kit
(1) Refer to Perkins Engine Company Limited.
- Suitable Temperature Adapter
MULTIMETER
Note: For more information on the Electronic Service
2900A038 Harness as
Tool and the PC requirements, refer to the
documentation that accompanies the software for the
Electronic Service Tool.
Perkins Electronic Service Tool
Connecting the Electronic Service Tool
The Electronic Service Tool can display the following
information: and the TIPSS Adapter
• Status of all pressure sensors and temperature
sensors
• Programmable parameter settings

• Active diagnostic codes and logged diagnostic
codes
• Logged events
• Histograms
The Electronic Service Tool can also be used to
perform the following functions:
• Diagnostic tests
• Calibrations
• Programming of flash file

• Parameter programming
• Copy configuration function for Electronic Control

Module (ECM) replacement
• Data logging
• Graphs (real time)

Table 3 lists the service tools that are required in
order to use the Electronic Service Tool. Illustration 7 g01121866
Table 3 (1) Personal Computer (PC)
(2) Adapter Cable (Computer Serial Port)
Service Tools for the Use of the Electronic Service (3) TIPSS adapter
Tool (4) Adapter Cable Assembly
Part Number Description
Note: Items (2), (3) and (4) are part of the TIPSS
-(1) Single Use Program License adapter kit.
Use the following procedure in order to connect the
(continued)
Electronic Service Tool and the TIPSS Adapter.
1. Turn the keyswitch to the OFF position.
14 UENR4504
2. Connect cable (2) between the “COMPUTER” 2. Connect cable (2) between the “COMPUTER”
end of TIPSS adapter (3) and the RS232 serial end of CA3 adapter (3) and a USB port of PC (1).
port of PC (1).
3. Connect cable (4) between the “DATA LINK” end
Note: The Adapter Cable Assembly(4) is required to of CA3 adapter (3) and the service tool connector.
connect to the USB port on computers that are not
equipped with an RS232 serial port. 4. Place the keyswitch in the ON position. If the
Electronic Service Tool and the CA3 adapter do
3. Connect cable (4) between the “DATA LINK” end not communicate with the Electronic Control
of TIPSS adapter (3) and the service tool Module (ECM), refer to the diagnostic procedure
connector. Troubleshooting, “Electronic Service Tool Does
4. Place the keyswitch in the ON position. If the Not Communicate”.
Electronic Service Tool and the TIPSS adapter do
not communicate with the Electronic Control i05857081
Module (ECM), refer to the diagnostic procedure

Troubleshooting, “Electronic Service Tool Does
Indicator Lamps
Not Communicate”.
Connecting the Electronic Service Tool Indicator Lamps

and the CA3 Kit Seven lamps are available as options.
• “Shutdown” lamp
• “Warning” lamp
• “Wait to start” lamp

• “Low oil pressure” lamp
• “Emissions system failure” lamp

• “Low DEF” lamp
• “DEF quality” lamp
Functions of the Lamps

Shutdown Lamp
Lamp check – When the keyswitch is turned to ON,
the lamp will come on for 2 seconds. The lamp will
then go off unless there is an active warning.
On – The lamp will be on when the shutdown level in
the engine protection strategy has been reached. The
“Warning” lamp will also be on.
Warning Lamp
Illustration 8 g01121866 Lamp check – When the keyswitch is turned to ON,
(1) Personal Computer (PC)
(2) Adapter Cable (Computer Serial Port) then go off unless there is an active warning.
(3) CA3 adapter
(4) Adapter Cable Assembly Flashing – The lamp will be flashing when a
“warning” or a “warning and derate” is active.
Note: Items (2), (3) and (4) are part of the CA3 kit. On – The lamp will be on when a diagnostic code is
active.
Use the following procedure in order to connect the
Electronic Service Tool and the CA3 Adapter.
1. Turn the keyswitch to the OFF position.
UENR4504 15
Wait to Start Lamp

then go off unless “Wait to Start” is active.
On – The lamp is on during a “Wait to Start” period.
Low Oil Pressure Lamp

On – The lamp will come on when a low oil pressure
event is detected. The “Warning” lamp and the
“Shutdown” lamp may also come on.
Emissions System Failure Lamp

On – The lamp will be on when there is a fault in the
aftertreatment system. The “Warning” lamp may also
be on or flashing.
Low DEF Lamp

On – The lamp will be on when the fluid level in the
Diesel Exhaust Fluid (DEF) tank is low.
Flashing – The lamp will be flashing when the DEF
tank is empty.
DEF Quality Lamp

On – The lamp will be on when the DEF
concentration is out of the acceptable range.
Color of Lamps
Typically, the “Shutdown” lamp is colored red and
the “Warning” lamp is colored amber. The color of
the other lamps can vary.
16 UENR4504
Operation of the Indicator Lamps

Table 4
Warning Shutdown Low DEF DEF Quality Emissions Sys- Description of the Indication Engine State
Lamp Lamp Lamp Lamp tems
(Alert (Action FailureLamp
Lamp) Lamp)
On On On On On When the keyswitch is moved to The keyswitch is in the
the ON position, the lamps come ON position but the en-
on for 2 seconds and the lamps gine has not yet been
will then go off. cranked.
Off Off Off Off Off With the engine in operation, there The engine is operating
are no active warnings, diagnostic with no detected faults.
codes, or event codes.
On Off Off Off Off If the warning lamp comes on dur- The engine is operating
ing engine operation, the lamp in- normally but there is one
dicates that an active diagnostic or more faults with the
code (an electrical fault) is electronic management
present. system for the engine.
Slow Flash Off Off Off Off If the warning lamp flashes during The engine is operating
engine operation, an active diag- but there is one or more
nostic code is present. The diag- active diagnostic codes
nostic is sufficiently serious in that have initiated an en-
order to cause an engine derate. gine derate.
Fast Flash On Off Off Off If the warning lamp flashes and The engine is either
the shutdown lamp comes on dur- shutdown or an engine
ing engine operation, one of the shutdown is imminent.
following conditions exists: One or more monitored
engine parameters have
1. One or more of the shutdown exceeded the limit for an
values for the engine protection engine shutdown. This
strategy has been exceeded. pattern of lamps can be
caused by the detection
2. A serious active diagnostic code of a serious active diag-
has been detected. nostic code.
After a short time, the engine will

shut down.
Off Off On Off Off The level of fluid in the DEF tank is The engine is operating
below 10%. normally. This lamp
warns the operator that
the DEF tank requires
refilling.
On Off On Off On The level of fluid in the DEF tank is An active event code is
below 5%. raised.
Slow Flash Off On Off Slow Flash The level of fluid in the DEF tank is An active event code is
0%. raised. The engine will
be derated.
Fast Flash On Fast Flash Off Fast Flash The level of fluid in the DEF tank If shutdowns are en-
has been 0% for at least 40 abled, then the engine
minutes. will be shut down. After a
further 30 minutes the
engine will be com-
manded to low idle.
Off Off Off On Off The DEF quality is out of the ac- The engine is operating
ceptable range. normally. This lamp
warns the operator that
the DEF quality is
incorrect.
(continued)
UENR4504 17
(Table 4, contd)
Warning Shutdown Low DEF DEF Quality Emissions Sys- Description of the Indication Engine State
Lamp Lamp Lamp Lamp tems
(Alert (Action FailureLamp
Lamp) Lamp)
On Off Off On On The DEF quality has been out of An active event code is
the acceptable range for at least raised.
50 minutes.
Slow flash Off Off On Slow Flash The DEF quality has been out of An active event code is
range for at least 140 minutes. raised. The engine will
be derated.
Fast Flash On Off On Fast Flash The DEF quality has been out of If shutdowns are en-
the acceptable range for at least abled, then the engine
350 minutes. will be shut down. After a
further 240 minutes the
engine will be com-
manded to low idle.
On Off Off Off On There is an active diagnostic code The engine is operating
for a Exhaust Gas Recirculation normally unless the com-
(EGR) system or SCR component. ponent fault causes an
engine derate. In this
case, the warning lamp
will flash. An active event
code will be raised.
Slow Flash Off Off Off Slow Flash There has been an active diagnos- An active event code is
tic code for an EGR or SCR com- raised. The engine will
ponent for at least 25 minutes. be derated.
Fast Flash On Off Off Fast Flash There has been an active diagnos- An active event code is
tic code for an EGR or SCR com- raised. The engine will
ponent for at least 115 minutes. be derated. If shutdowns
are enabled, then the en-
gine will be shut down.
After a further 180 mi-
nutes the engine derate
will become more se-
vere. 210 minutes after
that point, the engine will
be commanded to low
idle.
i05857949 Note: Ensure that the ECM is receiving power and

that the ECM is properly grounded before
Replacing the ECM replacement of the ECM is attempted. Refer to the
schematic diagram.
Use the electronic service tool to read the parameters
NOTICE in the suspect ECM. Record the parameters in the
suspect ECM. Install the flash file into the new ECM.
Keep all parts clean from contaminants. After the ECM is installed on the engine, the
Contaminants may cause rapid wear and shortened parameters must be programmed into the new ECM.
component life.
NOTICE
If the flash file and engine application are not
The engine is equipped with an Electronic Control matched, engine damage may result.
Module (ECM). The ECM contains no moving parts.
Follow the troubleshooting procedures in this manual
in order to be sure that replacing the ECM will correct Perform the following procedure in order to replace
the problem. Verify that the suspect ECM is the cause the ECM.
of the problem.
1. Connect the electronic service tool to the
diagnostic connector.
18 UENR4504
2. From the menu bar go to the following menu • ECM Replacement

options:
9. Click on “Load From File” at the bottom of the
• Service screen.
• Copy Configuration 10. Select the correct ECM replacement file. Check
that the date and time stamp matches that of the
• ECM Replacement desired replacement file and click on “OK” .
3. Click on “Load From File” at the bottom of the 11. Click on “Program ECM” at the bottom of the
screen. screen.
4. Once the ECM data has been loaded, click on 12. Once the “Programming Complete” dialog box
“Save to File” at the bottom of the screen. Select a appears on screen, click on “OK” .
folder location and click on “Save” .
13. Check for logged diagnostic codes.
5. Remove the ECM. Refer to Disassembly and
Assembly, “Electronic Control Module - Remove
i04628911
and Install”.
6. Install the replacement ECM. Refer to Disassembly Self-Diagnostics
and Assembly, “Electronic Control Module -
Remove and Install”.
The Electronic Control Module (ECM) can detect
7. Download the flash file. faults in the electronic system and with engine
operation. A self-diagnostic check is also performed
a. Connect the electronic service tool to the whenever power is applied to the ECM.
diagnostic connector.
When a fault is detected, a diagnostic trouble code is
b. Select “WinFlash” from the “Utilities” menu generated. This code conforms to the SAE J1939
on the electronic service tool. standard. An alarm may also be generated.
Note: If “WinFlash” will not communicate with the Diagnostic Trouble Code – When a fault in the
electronic system is detected, the ECM generates a
ECM, refer to Troubleshooting, “Electronic Service diagnostic trouble code. The diagnostic trouble code
Tool Does Not Communicate”. indicates the specific fault in the circuitry.
c. Select the engine ECM under the “Detected
ECMs” . Diagnostic codes can have two different states:
d. Press the “Browse” button in order to select • Active
the part number of the flash file that will be
programmed into the ECM. • Logged
e. When the correct flash file is selected, press Active Code – An active diagnostic code indicates
that an active fault has been detected by the control
the “Open” button. system. Active codes require immediate attention.
Always service active codes prior to servicing logged
f. Verify that the “File Values” match the codes.
application. If the “File Values” do not match
the application, search for the correct flash file. Logged Code – Many generated codes are stored in
the permanent memory of the ECM. The codes are
g. When the correct flash file is selected, press logged for 100 operating hours unless a code is
cleared by use of the electronic service tool.
the “Begin Flash” button.
h. The electronic service tool will indicate when Logged codes may not indicate that a repair is
flash programming has been successfully needed. The fault may have been temporary. The
completed. fault may have been resolved since the logging of the
code. If the system is powered, an active diagnostic
8. From the menu bar go to the following menu trouble code may be generated whenever a
component is disconnected. When the component is
options: reconnected, the code is no longer active. Logged
codes may be useful to help troubleshoot intermittent
• Service faults. Logged codes can also be used to review the
performance of the engine and the electronic system.
• Copy Configuration
UENR4504 19
i05949806
Sensors and Electrical Connectors

854F-E34TA Engine
Sensors and electrical connector locations on the left side of the 854F-E34TA engine
(1) High-pressure fuel pump inlet metering (3) 62-pin engine interface connector (6) Oil pressure switch
valve (4) Fuel temperature sensor (7) Primary speed/timing sensor (crankshaft)
(2) 10-pin engine interface connector (5) Fuel rail pressure sensor (8) Water In Fuel (WIF) sensor
20 UENR4504
Sensors and electrical connector locations on the left side of the 854F-E34TA engine
(1) High-pressure fuel pump inlet metering (3) 62-pin engine interface connector (6) Oil pressure switch
valve (4) Fuel temperature sensor (7) Primary speed/timing sensor (crankshaft)
(2) 10-pin engine interface connector (5) Fuel rail pressure sensor (8) Water In Fuel (WIF) sensor
UENR4504 21
Sensors and electrical connector locations on the right side of the 854F-E34TA engine
(9) Exhaust Gas Recirculation (EGR) valve (12) Exhaust gas pressure sensor (16) Secondary (camshaft) speed/timing
(10) Intake manifold air pressure and (13) Intake throttle valve sensor
temperature sensor (14) Coolant temperature sensor
(11) Exhaust temperature sensor connector (15) Wastegate regulator
22 UENR4504
Clean Emissions Module (CEM)
Typical view of the sensor locations on the CEM on 854F-E34TA
(17) Engine out NOx sensor (19) Diesel Oxidation Catalyst (DOC)/DEF (20) DOC inlet temperature sensor
(18) Diesel Exhaust Fluid (DEF) injector mixing chamber module
UENR4504 23
Typical view of the sensor locations on the CEM on 854F-E34TA
(21) Inlet air temperature sensor (26) Selective Catalytic Reduction (SCR) (31) Heated DEF line
(22) Breather heater catalyst (32) DEF tank
(23) Heater Control Unit (HCU) (27) DEF pump module (33) DEF tank header unit
(24) Glow plug Control Unit (GCU) (28) SCR inlet/outlet temperature sensors (34) Engine Electronic Control Module
(25) Coolant diverter valve (29) Ammonia sensor (ECM)
(30) Tailpipe out NOx sensor
i05949819
Engine Wiring Information
Harness Wire Identification

Note: In the following diagrams, “Pxxx” signifies a
plug and “Jxxx” signifies a jack.
24 UENR4504
Schematic Diagrams
UENR4504 25
854F-E34TA Engine
26 UENR4504
Schematic diagram of the wiring between the engine components and the engine interface connections
UENR4504 27
Wiring from the Engine to the Electronic Control Module (ECM)
Schematic diagram of the wiring between the engine interface connectors and the Electronic Control Module (ECM).
28 UENR4504
Schematic diagram for the aftertreatment system components
UENR4504 29
Wiring for the Application
30 UENR4504
Schematic diagram for a typical application
UENR4504 31
i04035775 • Diagnostics
ECM Harness Connector • Diagnostic Tests

Terminals • Override Parameters
Glow Plug Starting Aid Override

The Electronic Control Module (ECM) uses a
connector with 60 terminals (J2) and a connector with This override is used to check that the glow plugs are
94 terminals(J1) to interface to the wiring harness. functioning correctly. The override will remain active
until switched off using the electronic service tool.
DEF Pressure Line Heater Override

This override switches on the line heater for the DEF
pressure line. The override will remain active until
switched off using the electronic service tool.
DEF Backflow and Suction Line Heater

Override
This override switches on the line heater for the DEF
return line and the DEF suction line. The override will
remain active until switched off using the electronic
service tool.
Typical view of the pin layout on the J2 connector DEF Pump Heater Override
This override switches on the heater for the DEF
pump module. The override will remain active until
switched off using the electronic service tool.
Active Diagnostic Codes

The purpose of this screen is to show all of the active
diagnostic codes.
In the electronic service tool, select the engine ECM.
Select the “Diagnostics” tab.
Select the “Active Diagnostic Codes” tab.
Logged Diagnostic Codes

The purpose of this screen is to show all of the logged
Typical view of the pin layout on the J1 connector diagnostic codes. Logged diagnostic codes will be
cleared from the “Logged Diagnostic Codes” screen
i05867012 when the code has not been active for 40 hours.
In the electronic service tool, select the engine ECM.
Service Tool Features
Select the “Diagnostics” tab.
Select the “Logged Diagnostic Codes” tab.
Override Parameters
Diagnostic Tests
The override parameters screen has multiple
overrides. The parameters control various functions Electronic service tool diagnostic tests are listed
on the engine and the aftertreatment. These functions below.
and features allow the technician to troubleshoot
different engine systems. Select the “Diagnostics” tab.
Navigate to the following menu options in the Select the “Diagnostic Tests” tab.
electronic service tool in order to access the
“Override Parameters” :
32 UENR4504
Cylinder Cutout Select the “Calibrations” tab.
This test can disable individual cylinders to while the Calibrations Listed in the Engine ECM
engine is running to help identify cylinders that are
performing below the required level. Menu
Click “Change” for an individual cylinder in order to
switch off that cylinder manually. This test can be Injector Codes Calibration
used to identify faults by listening to the sound of the
engine as a cylinder is disabled. If there is no change Whenever an injector is replaced, the injector must be
in the sound of the engine as a cylinder is disabled, trimmed. Trimming the injector calibrates all of the
this may indicate a fault in that cylinder. injectors to deliver the same amount of fuel. The
Injector Codes Calibration allows the injector trim
code information to be programmed into the ECM.
Fuel Rail Pressure Test After the injector is calibrated, the calibration data is
checked for validity.
This test raises the fuel pressure in the high-pressure
fuel rail to 180000 kPa (26107 psi) for one minute at When new injectors are installed, record the serial
1300 rpm. numbers of each injector and input using the
electronic service tool. Refer to Troubleshooting,
After this test has been run, and the fuel pressure has “Injector Code - Calibrate” for more information.
been allowed to drop to a safe level, the fuel system
can be inspected for signs of leakage.
Component Replacement Resets
DEF Dosing System Accuracy Test In the electronic service tool, go to the “Service”
menu.
This test is used with the DEF Test Kit to measure
the amount of DEF that the SCR dosing system is Oxidation Catalyst Replacement Reset
delivering. The test can also be used to confirm that
there is an acceptable spray pattern from the DEF Use this reset when the Diesel Oxidation Catalyst
Injector. (DOC) is replaced.
Note: The DEF injector must be removed from the
exhaust system during this test and placed in an EGR Valve Learn Reset
appropriate container. Failure to do so could result in
issues with the SCR system operation. Refer to Use this reset when the Exhaust Gas Recirculation
(EGR) valve is replaced.
Testing and Adjusting, “Aftertreatment SCR System
Dosing Test”.
Rail Pressure Valve Learn Reset
DEF Dosing System Purge Test Use this reset when the fuel rail pressure valve is
replaced. This reset will reset the counter in the ECM
This test verifies that the DEF purging process is for the number of times that the pressure relief valve
working correctly by purging the DEF pump and lines. has opened.
This service test is used to purge the DEF system.
This test turns on the DEF purging pump, causing the Rail Pressure Sensor Replacement Reset
DEF to be pumped from the injector back into the
tank. Purging allows the system to de-pressurize and Use this reset when the fuel rail pressure sensor is
empty prior to repair work. replaced.
DEF Dosing System Verification Test SCR Catalyst Replacement Reset

This test primes the dosing system. The test is used Use this reset when the SCR catalyst is replaced.
to ensure that the DEF pump is able to build
adequate pressure. NOx Sensor Replacement Reset
This test turns on the DEF pump. During this time, the
DEF pump will pressurize the entire DEF dosing Use this reset when either the engine out NOx sensor
system. The DEF injector will open briefly. The DEF or the tailpipe out NOx sensor is replaced. Also use
pump will purge the system at the end of the test. this reset if both NOx sensors are replaced.
Calibrations EGR Cooler Replacement Reset

In the electronic service tool, go to the following menu Use this reset when either the Exhaust Gas
options: Recirculation (EGR) cooler is replaced.
Select the “Service” tab.
UENR4504 33
Engine Emissions Operator Inducement

Safe Harbor Reset
When an operator inducement has shut down the
engine, the engine can be restarted and run for a
maximum of 30 minutes. Each time the engine is
restarted a counter in the ECM will increase by one.
Once the counter reaches three, the engine will only
run at low idle.
The “Safe Harbor Reset” will reset the counter to
zero.
Note: Only use this reset when the fault that caused
the inducement has been repaired or if the engine
needs to be started as part of the troubleshooting
process.
34 UENR4504
d. Verify that the “File Values” match the
application. If the “File Values” do not match
the application, search for the correct flash file.
i04035800 e. When the correct flash file is selected, press

the “Begin Flash” button.
f. The electronic service tool will indicate when
flash programming has been successfully
The electronic service tool can be used to view completed.
certain parameters that can affect the operation of the
engine. The electronic service tool can also be used 6. Access the “Configuration” screen under the
to change certain parameters. The parameters are “Service” menu in order to determine the
stored in the Electronic Control Module (ECM). parameters that require programming.
i04215913 7. Start the engine and check for proper operation.

Check that there are no active diagnostic codes.
Flash Programming
“ WinFlash”” Error Messages
Flash Programming – A method of loading a flash If any error messages are displayed during flash
file into the Electronic Control Module (ECM) programming, click on the “Cancel” button in order to
stop the process. Access the information about the
“ECM Summary” under the “Information” menu.
The electronic service tool is utilized to flash program Ensure that you are programming the correct flash file
a flash file into the ECM. The flash programming for your engine.
transfers the flash file from the PC to the ECM.
Flash Programming a Flash File i05867872
1. Obtain the part number for the new flash file. Injector Code - Calibrate
Note: If you do not have the part number for the flash
file, use “PTMI” on the Perkins secured web site. Injector codes are seven digit alphanumerical codes
that are supplied with each injector. The code is
Note: You must have the engine serial number in printed on the injector . The code is used by the
order to search for the part number of the flash file. Electronic Control Module (ECM) to balance the
performance of the injectors.
diagnostic connector. The electronic service tool is used to load the injector
codes into the ECM.
3. Turn the keyswitch to the ON position. Do not start
The injector codes must be loaded into the ECM if
the engine. any of the following conditions occur:
4. Select “WinFlash” from the “Utilities” menu on • An electronic unit injector is replaced.
the electronic service tool.
• The ECM is replaced.
Note: If “WinFlash” will not communicate with the
ECM, refer to Troubleshooting, “Electronic Service • Electronic unit injectors are exchanged between
Tool Does Not Communicate”. cylinders.
5. Flash program the flash file into the ECM. • A 630-2 diagnostic code is active.
a. Select the engine ECM under the “Detected If the ECM is replaced, the injector codes are
ECMs” . normally transferred to the new ECM as part of the
“Copy Configuration” procedure. If the “Copy
b. Press the “Browse” button in order to select Configuration” procedure fails, the injector codes
the part number of the flash file that will be must be loaded manually.
programmed into the ECM. Installing Injector Codes
c. When the correct flash file is selected, press
the “Open” button.
UENR4504 35
Exchanging electronic unit injectors can help

determine if a combustion problem is in the electronic
unit injector or in the cylinder. If two electronic unit
injectors that are currently installed in the engine are
exchanged between cylinders, the injector codes
must also be exchanged. Record the injector trim
codes for the two injectors that are to be exchanged.
Use the electronic service tool to enter the injector
codes for the correct cylinders.
i05867904
Mode Switch Setup
The Mode Switches can be used to change the

performance characteristics of the engine. The
“Engine Operating Mode” configuration is located in
the “Configuration” screen of the electronic service
tool.
Engine High Idle Speed (RPM)

Typical example of an electronic unit injector This parameter represents the maximum engine
(1) Location of the injector code
speed when the mode switch is not installed or when
the switch is in the OFF position.
Table 5
1. Record the injector code for each electronic unit
injector. Min Max
1500 rpm 2800 rpm
diagnostic connector. Refer to Troubleshooting,
“Electronic Service Tools”. High Idle Droop Percentage
3. Turn the keyswitch to the ON position. This parameter represents the amount of droop that
is applied to the high idle.
4. Select the following menu options on the electronic
Table 6
service tool:
Minimum Maximum
• Service 5 percent 10 percent
• Calibrations
• Injector Trim Calibration Throttle #1 Droop Percentage

5. Select the appropriate cylinder. This parameter represents the amount of droop that
is applied to the “Throttle 1” input.
6. Click on the “Change” button. Table 7
Minimum Maximum
7. Input the applicable injector code that was
recorded in Test Step 1. 0 percent 10 percent
8. Click on the “OK” button.

Throttle #2 Droop Percentage
The injector code is loaded into the ECM.
This parameter represents the amount of droop that
9. Repeat the procedure for each cylinder, as is applied to the “Throttle 2” input.
required. Table 8
Exchanging Electronic Unit Injectors Minimum Maximum

0 percent 10 percent
36 UENR4504
TSC1 Droop Percentage Table 14

Minimum Maximum
is applied to the “Torque Speed Control 1(TSC1)” 0 percent 10 percent
input.
Table 9
Minimum Maximum Engine Operating Mode #2 High
Idle Speed
This parameter defines the high idle speed when
mode 2 is selected.
Engine Operating Mode #1 High Table 15
Idle Speed Minimum Maximum
This parameter defines the high idle speed when 1500 rpm 2800 rpm
mode 1 is selected.
Table 10
Minimum Maximum Engine Operating Mode #2 High
1500 rpm 2800 rpm
Idle Droop Percentage
is applied to the high idle when mode 2 is selected.
Engine Operating Mode #1 High Table 16
Idle Droop Percentage Minimum Maximum
This parameter represents the amount of droop that 5 percent 10 percent
is applied to the high idle when mode 1 is selected.
Table 11
Minimum Maximum Engine Operating Mode #2 Throttle
#1 Droop Percentage
is applied to the “Throttle 1” input when mode 2 is
Engine Operating Mode #1 Throttle selected.
#1 Droop Percentage Table 17
Minimum Maximum
is applied to the “Throttle 1” input when mode 1 is 0 percent 10 percent
selected.
Table 12
Minimum Maximum Engine Operating Mode #2 Throttle
#2 Droop Percentage
Engine Operating Mode #1 Throttle selected.
#2 Droop Percentage Table 18
Minimum Maximum
is applied to the “Throttle 2” input when mode 1 is 0 percent 10 percent
selected.
Table 13
Minimum Maximum Engine Operating Mode #2 TSC1
Droop Percentage
is applied to the “Torque Speed Control 1(TSC1)”
Engine Operating Mode #1 TSC1 input when mode 2 is selected.
Droop Percentage Table 19
Minimum Maximum
is applied to the “Torque Speed Control 1(TSC1)” 0 percent 10 percent
input when mode 1 is selected.
UENR4504 37
Engine Operating Mode #3 High i05920711
Idle Speed Throttle Setup

This parameter defines the high idle speed when
mode 3 is selected.
Table 20 There are two separate channels for throttle input.
Minimum Maximum The two channels can have any combination of an
analog throttle or a multi-position switched throttle.
1500 rpm 2800 rpm
The Electronic Control Module (ECM) must be
programmed for the type of throttle input that is being
Engine Operating Mode #3 High used in either position. From the menu, select
“Services” , then “Configuration” . On the
Idle Droop Percentage “Configuration” screen, select “Throttle
Configuration” to set up the analog throttle or select
This parameter represents the amount of droop that “PTO and Throttle Lock Parameters” to set up the
is applied to the high idle when mode 3 is selected. multi-position throttle switch.
Table 21
Minimum Maximum
Engine Operating Mode #3 Throttle

#1 Droop Percentage
selected.
Table 22
Minimum Maximum
Engine Operating Mode #3 Throttle

#2 Droop Percentage
This parameter represents the amount of droop that Illustration 21 g02233193
is applied to the “Throttle 2” input when mode 3 is Typical Range of Throttle
selected.
Table 23 (1) Lower Diagnostic Limit
(2) Initial Lower Position
Minimum Maximum (3) Idle Validation Minimum Off Threshold
(4) Idle Validation Maximum On Threshold
0 percent 10 percent (5) Initial Upper Position
(6) Upper Diagnostic Limit
Engine Operating Mode #3 TSC1 Analog throttles require additional programming. If a

multi-position switch is selected, refer to the
Droop Percentage Troubleshooting Guide, “Multiposition Switch Setup”.
If an analog throttle is selected, the following
This parameter represents the amount of droop that parameters can be programmed into the ECM.
is applied to the “Torque Speed Control 1(TSC1)”
input when mode 3 is selected. Throttle Enable Status
Table 24
This parameter defines which analog throttle inputs
Minimum Maximum are used.
0 percent 10 percent Table 25
Value
Disabled
Throttle #1
Throttle #1 and Throttle #2
Throttle #2
38 UENR4504
Throttle #1 Initial Lower Position Table 30
This parameter is the voltage that will be interpreted Minimum Maximum

by the ECM as zero throttle. This parameter has a 0.4 VDC 1.6 VDC
tolerance to make an allowance for manufacturing
differences between throttle pedals.
Table 26 Throttle #1 Lower Diagnostic Limit
Minimum Maximum
This parameter is the minimum voltage that should be
0.4 VDC 1.6 VDC detected by the ECM in normal operation when the
pedal is in the “off” position. A value below this limit
will generate a open circuit or voltage below normal
Throttle #2 Initial Upper Position diagnostic code. The range of this diagnostic
detection area is from 0 VDC to the programmed
This parameter is the voltage that will be interpreted value for the lower position limit.
by the ECM as full throttle. This parameter has a Table 31
tolerance to make an allowance for manufacturing
differences between throttle pedals. Minimum Maximum
Table 27 0 VDC 1.6 VDC
Minimum Maximum
3.6 VDC 4.6 VDC Throttle #1 Upper Diagnostic Limit
This parameter is the minimum voltage that is
Throttle #1 Idle Validation Switch detected by the ECM in normal operation when the
pedal is in the maximum position. A value above this
Enable Status limit will generate a short circuit or voltage above
All analog throttles can have an Idle Validation Switch normal diagnostic code. The range of this diagnostic
(IVS). If this parameter is programmed to “Yes” , the detection area is from the programmed value of the
ECM will look for this switch input on pin J1:67 for Idle upper position limit to 5 VDC.
Validation Switch 1 (IVS1) and J1:42 for Idle Table 32
Validation Switch 2 (IVS2). Minimum Maximum
Table 28
3.6 VDC 5 VDC
Values
No
Yes Throttle #2 Initial Lower Position
This parameter is the voltage that will be interpreted
by the ECM as zero throttle. This parameter has a
Throttle #1 Idle Validation Minimum tolerance to make an allowance for manufacturing
Off Threshold differences between throttle pedals.
Table 33
This parameter is the minimum voltage that will be
detected by the ECM when the IVS is ON (Closed). Minimum Maximum
0.4 VDC 1.6 VDC
If the ECM detects a voltage below this value with the
IVS OFF (Open), a fault code will be generated and
the engine will remain at idle.
Table 29
Throttle #2 Initial Upper Position
Minimum Maximum This parameter is the voltage that will be interpreted
by the ECM as full throttle. This parameter has a
0.4 VDC 1.6 VDC tolerance to make an allowance for manufacturing
differences between throttle pedals.
Table 34
Throttle #1 Idle Validation Maximum
Minimum Maximum
On Threshold
3.6 VDC 4.6 VDC
This parameter is the maximum voltage that will be
detected by the ECM when the IVS is OFF (Open) .
When the idle validation switch is OFF (Open) and
the ECM detects a signal that is higher than the
programmed value for IVS Max ON, the ECM will
generate a fault code and the engine will remain at
idle.
Refer to Table 30 and Table 30 .
UENR4504 39
Throttle #2 Idle Validation Switch Throttle #2 Upper Diagnostic Limit

Enable Status This parameter is the minimum voltage that is
All analog throttles can have an Idle Validation Switch detected by the ECM in normal operation when the
(IVS). If this parameter is programmed to “Yes” , the pedal is in the maximum position. A value above this
ECM will look for this switch input on pin J1:76 for Idle limit will generate a short circuit or voltage above
Validation Switch 1 (IVS1) and J1:42 for Idle normal diagnostic code. The range of this diagnostic
Validation Switch 2 (IVS2). detection area is from the programmed value of the
upper position limit to 5 VDC.
Table 35
Table 39
Values
Minimum Maximum
No
Yes 3.6 VDC 5 VDC
i05867907
Throttle #2 Idle Validation Minimum
Off Threshold Multiposition Switch Setup
This parameter is the minimum voltage that will be
detected by the ECM when the IVS is ON (Closed).
Note: The multi-position throttle switch can only be
If the ECM detects a voltage below this value with the enabled if the optional PTO switches are not installed.
IVS OFF (Open), a fault code will be generated and
the engine will remain at idle. The multi-position throttle switch is an optional throttle
Table 36 input. A maximum of four switch positions can be
used.
Minimum Maximum
When the “Multi-Position Throttle Switch” option is
0.4 VDC 1.6 VDC
selected as the “Throttle Lock Feature Installation
Status” in the electronic service tool, additional
information is required.
Throttle #2 Idle Validation Maximum
On Threshold Multi State Input Switch Enable
This parameter is the maximum voltage that will be Status
detected by the ECM when the IVS is OFF (Open) . This parameter must be set to “Enabled” if a multi-
When the idle validation switch is OFF (Open) and position switch is installed on the application.
the ECM detects a signal that is higher than the
Table 40
programmed value for IVS Max ON, the ECM will
generate a fault code and the engine will remain at Value
idle.
Enabled
Table 37 Disabled
Minimum Maximum
0.4 VDC 1.6 VDC
Mode Select Enable/Disable
This parameter defines the function of the multi state
Throttle #2 Lower Diagnostic Limit input switch.
Table 41
This parameter is the minimum voltage that should be
detected by the ECM in normal operation when the Value
pedal is in the “off” position. A value below this limit Mode Select Switch
will generate a open circuit or voltage below normal PTO Mode/Multi Position Throttle Switch
diagnostic code. The range of this diagnostic
detection area is from 0 VDC to the programmed
value for the lower position limit.
Throttle Lock Maximum Engine
Table 38
Speed
Minimum Maximum
0 VDC 1.6 VDC This parameter defines the maximum engine speed
the multi position throttle switch can control to when
enabled.
Table 42
Minimum Maximum Default
0 rpm 2800 rpm 1.05 times rated
speed
40 UENR4504
Throttle Position #1 Engine Speed

The “Engine Speed” is the programmed engine rpm
for a particular position of the multi-position throttle
switch.
Table 43
0 rpm 2800 rpm 800 rpm

switch.
Table 44

switch.
Table 45

switch.
Table 46
UENR4504 41
Customer Specified Engine Idle Shutdown Warning Time
Parameters This parameter defines the amount of time that a

warning is raised before the engine is shut down.
Table 50
Minimum Maximum
i05867969 Less than “Engine Idle Shut-

0
down Delay Time”
Customer Specified
Parameters PTO and Throttle Lock Parameters
Throttle Lock Feature Installation Status
Customer specified parameters allow the engine to
be configured to the exact needs of the application. Note: PTO and a multi-position throttle switch cannot
be installed at the same time.
Customer parameters may be changed repeatedly as
operational requirements change. This parameter defines the switch input for the PTO/
Throttle lock function.
The following information is a brief description of the Table 51
customer specified parameters. The following
parameter values are included with the descriptions: Value
Multi Position Throttle Switch
• Minimum None
Raise/Lower Switch
• Maximum
Speed Control Multi-State Input Switch Enable Status

Low Idle Speed This parameter should be set to “Enabled” if a multi-
position switch is installed on the application. Refer to
The “Low Idle Speed” parameter is the minimum Troubleshooting, “Multiposition Switch Setup” or refer
engine rpm. to Troubleshooting, “Mode Switch Setup” for more
Table 47 information on configuring the multi-state switches.
Table 52
Minimum Maximum
Value
800 rpm 1200 rpm
Enabled
Disabled
Engine Idle Shutdown
Throttle Lock Engine Set Speed #1
Engine Idle Shutdown Enable Status
The “Throttle Lock Engine Set Speed 1” parameter
If the “Engine Idle Shutdown Enable Status” is the engine speed that can be selected in the PTO
parameter is set to “Enabled” , the engine will shut Set/Resume mode.
down after a pre-set duration at low idle and the
Table 53
machine is in a safe state. Refer to “Machine Idle
Status Input Configuration” . Minimum Maximum
Table 48
800 rpm 1300 rpm
Value
Enabled
Disabled Throttle Lock Increment Speed Ramp
Rate
Engine Idle Shutdown Delay Time The “Throttle Lock Increment Speed Ramp Rate”
parameter is the rate of engine acceleration when the
This parameter defines the amount of time the engine PTO switch is held in the ACCELERATE position.
can remain at idle when the machine is in a safe state Table 54
before the engine is shut down.
Table 49
Minimum Maximum
Minimum Maximum 0 rpm/sec 500 rpm/sec
0 hours 277 hours
42 UENR4504
Throttle Lock Decrement Speed Ramp Hydrocarbon Elevated Idle Speed

Rate This parameter defines the engine speed that the idle
The “Throttle Lock Decrement Speed Ramp Rate” speed is elevated to when there is excessive
parameter is the rate of engine deceleration when the hydrocarbon build-up in the aftertreatment system
PTO switch is held in the DECELERATE position. and the application is in a safe state.
Table 60
Table 55
Minimum Maximum
Minimum Maximum
1100 rpm 1200 rpm
0 rpm/sec 500 rpm/sec
Throttle Lock Engine Set Speed Engine Acceleration Rate

Increment The “Engine Acceleration Rate” parameter is the
acceleration rate for the engine under normal
The “Throttle Lock Engine Set Speed Increment” operating conditions.
parameter controls the increase in engine speed Table 61
when the PTO switch is briefly operated to
ACCELERATE. Minimum Maximum
Table 56 0 rpm/second 1000 rpm/second
Minimum Maximum
0 rpm 50 rpm
Configurable Inputs
Throttle Lock Maximum Engine Speed Air Filter Restriction Switch Installation
Status
This parameter defines the maximum engine speed
when the PTO switch is held in the ACCELERATE An air filter restriction switch is an optional switch
position and the “Throttle Lock Feature Installation input. If an air filter restriction switch is installed on the
Status ” is set to “Raise/Lower Switch” . application, this parameter must be set to “Installed” .
Table 57
Minimum Maximum
Note: If the Air Filter Restriction Switch Installation
Status is set to “Not Installed” , the “Air Filter
0 rpm 2800 rpm Restriction Switch Configuration” must be set to
“Normally Open” .
Table 62
Miscellaneous Value
Monitoring Mode Shutdowns Installed

Not Installed
The “Monitoring Mode Shutdowns” parameter
controls the shutdown feature that is associated with
the engine monitoring feature. When this feature is Air Filter Restriction Switch
enabled, certain diagnostic codes will cause the Configuration
engine to be shut down in order to protect the engine
from damage.
A “Normally Open” or a “Normally Closed” air filter
Table 58 restriction switch can be connected to the ECM. This
Value parameter must be set for the type of switch that is
installed.
Disabled Table 63
Enabled
Value
Normally Closed (to Ground)
Limp Home Desired Engine Speed Normally Open
This parameter defines the maximum engine speed

when a fault is detected on the throttle signal from the
analog throttle position sensor or the Torque Speed
Control 1 (TSC1) CAN data link request.
Table 59
Minimum Maximum
800 rpm 1800 rpm
UENR4504 43
User Defined Shutdown Enable Status Shutdown Lamp Installation Status

A user-defined shutdown switch is an optional switch Table 69
input. Programming the “User Defined Shutdown
Value
Enable Status” parameter to “Enabled” notifies the
ECM that a user-defined switch input is present. If this Enabled
parameter is programmed to “Enabled” and the Disabled
user-defined shutdown switch closes, the engine will
shut down.
Table 64 Malfunction Indicator Lamp (MIL)
Value Installation Status
Enabled Table 70
Disabled
Value
Enabled
Machine Idle Status Input Configuration Disabled
This parameter defines the method that the ECM is

notified when the application is in a safe state for DEF Level Lamp Installation Status
“Engine Idle Shutdown” and “Hydrocarbon Elevated
Idle Speed” functions. Table 71
Table 65 Value
Value Enabled
Switch Disabled
Data Link
Switch and Data Link
DEF Quality Lamp Installation Status
Configurable Outputs Table 72
Value
Lamps Enabled
Disabled
The following parameters must be set to “Enabled” if
the relevant lamp is connected directly to the engine
ECM. Starter Relay Installation Status
Oil Pressure Lamp Installation Status This parameter must be set to “Enabled” if the
application is equipped with a start relay controlled by
Table 66 the engine ECM.
Value Table 73
Enabled Value
Disabled
Enabled
Disabled
Wait to Start Lamp Installation Status

Table 67
Low Pressure Fuel Pump Installation
Value
Status
Enabled This parameter must be set to “Enabled” if a low-
Disabled pressure fuel pump is installed on the application.
Table 74
Value
Warning Lamp Installation Status
Enabled
Table 68 Disabled
Value
Enabled
Disabled
44 UENR4504
Tachometer Output Configuration Throttle Arbitration Method

(Degrees per Pulse) The “Throttle Arbitration Method” parameter is
applicable to engines with more than one throttle
This parameter is used to configure the degrees per input. This parameter defines which throttle has
pulse if a tachometer is installed. control of the engine speed.
Table 75 Table 78
Minimum Maximum Value
0 degrees per pulse 360 degrees per pulse Largest wins
Smallest Wins
Manual
J1939 Continuous Fault Handling
These parameters define the engine software Manual Throttle Arbitration Precondition
reaction to faults on Torque Speed Control 1 (TSC1)
Check
Remote Torque Speed Control Enable This parameter is only applicable when the “Throttle
Status Arbitration Method” is set to manual. When this
parameter is enabled, the engine speed must be less
This parameter selects the TSC1 source address of than 1200 rpm and the active analog throttle position
the controlling device. Refer to the OEM must be less than 10 percent in order to switch the
analog throttle input.
documentation for more information.
Table 79
TSC1 Fault Reaction Value

Enabled
This parameter defines the engine software response Disabled
to a fault on the TSC request. If this parameter is
enabled, a fault on TSC1 will cause the engine speed
to go to “Limp Home Desired Engine Speed” . If this
parameter is disabled, a fault on TSC1 will cause the
Aftertreatment Configuration
engine speed control to switch to another valid speed
These parameters define the configuration of the
input (if available). aftertreatment that is installed on the application.
Table 76
Value Aftertreatment #1 DEF Tank
Enabled Configuration
Disabled
This parameter defines the DEF tank configuration.
Table 80
TSC1 Fault Handling
Value
When this parameter is set to enabled, the engine 19 Liter Landscape
software will monitor TSC1 faults as soon as the 19 Liter Portrait
keyswitch is turned to the ON position. When this
parameter is set to disabled, the engine software will
monitor TSC1 faults after the first TSC1 message is
received. DEF Tank Height Parameters
Table 77
These parameters are used to define the DEF tank
Value configuration if a custom DEF tank is installed. Refer
Enabled to the OEM documentation for more information.
Disabled
Throttle Configuration
Refer to Troubleshooting, “Throttle Setup” for more
information on configuring throttles.
UENR4504 45
i05870101
Customer Specified Parameters Table
46 UENR4504
Table 81
ECM Parameter Possible Values

Speed Control
“Low Idle Speed” 800 to 1200 rpm
Engine Idle Shutdown Enable Status Enabled

Disabled
Engine Idle Shutdown Delay Time 0 to 277 hours
Engine Idle Shutdown Warning Time 0 to “Engine Idle Shutdown Delay Time”
PTO and Throttle Lock Parameters

“Throttle Lock Feature Installation Status” Multi Position Throttle Switch
None
Raise/Lower Switch
Multi-State Input Switch Enable Status Enabled
Disabled
Mode Select Enable/Disable Enabled
Disabled
“Throttle Lock Engine Set Speed #1” 800 rpm to 1300 rpm
“Throttle Lock Increment Speed Ramp Rate” 0 to 500 rpm /sec
“Throttle Lock Decrement Speed Ramp Rate” 0 to 500 rpm /sec
“Throttle Lock Engine Set Speed Increment” 0 to 50 rpm
“Throttle Lock Maximum Engine Speed” 0 to rpm
Throttle Position #1 Engine Speed 0 to 2800 rpm
Miscellaneous
“Monitoring Mode Shutdowns” Disabled
Enabled
“Limp Home Desired Engine Speed” 800 rpm to 1800 rpm
“Hydrocarbon Elevated Idle Speed” 1100 rpm to 1200 rpm
“Engine Acceleration Rate” 0 to 1000 rpm/sec
Configurable Inputs
Air Filter Restriction Switch Installation Status Installed

Not Installed
Air Filter Restriction Switch Configuration Normally Closed (to ground)
Normally Open
“User Defined Shutdown Enable Status” Enabled

Disabled
“Machine Idle Status Input Configuration” Switch
Data Link
Switch and Data Link
Configurable Outputs
(continued)
UENR4504 47
(Table 81, contd)


Oil Pressure Lamp Installation Status Enabled
Disabled
Wait to Start Lamp Installation Status Enabled
Disabled
Warning Lamp Installation Status Enabled
Disabled
Shutdown Lamp Installation Status Enabled
Disabled
Malfunction Indicator Lamp (MIL) Installation Status Enabled
Disabled
DEF Level Lamp Installation Status Enabled
Disabled
DEF Quality Lamp Installation Status Enabled
Disabled
Starter Relay Installation Status Enabled
Disabled
Low Pressure Fuel Pump Installation Status Enabled
Disabled
Tachometer Output Configuration (Degrees per Pulse) 0 to 360 degrees per pulse
Remote Torque Speed Control Enable Status Various
TSC1 Fault Reaction Enabled

Disabled
TSC1 Fault Handling Enabled
Disabled
Throttle Arbitration Method Largest Wins

Smallest Wins
Manual
Manual Throttle Arbitration Precondition Check Enabled
Disabled
Disabled
Throttle #1
Throttle Enable Status
Throttle #1 and Throttle #2
Throttle #2
Throttle #1 Initial Lower Position 0.4 to 1.6 V
Throttle #1 Initial Upper Position 3.6 to 4.6 V
No
Throttle #1 Idle Validation Switch Enable Status
Yes
Throttle #1 Idle Validation Minimum OFF Threshold 0.4 to 1.6 V
Throttle #1 Idle Validation Maximum ON Threshold 0.4 to 1.6 V
Throttle #1 Lower Diagnostic Limit 0 to 1.6 V
Throttle #1 Upper Diagnostic Limit 3.6 to 5 V
Throttle #2 Initial Lower Position 0.4 to 1.6 V

Throttle #2 Initial Upper Position 3.6 to 4.6 V
(continued)
48 UENR4504
(Table 81, contd)


No
Yes
Throttle #2 Idle Validation Minimum OFF Threshold 0.4 to 1.6 V
Throttle #2 Idle Validation Maximum ON Threshold 0.4 to 1.6 V
Throttle #2 Lower Diagnostic Limit 0 to 1.6 V
Throttle #2 Upper Diagnostic Limit 3.6 to 5 V
Engine Operating Mode
High Idle Speed 1500 to 2800 rpm
High Idle Droop Percentage 5 to 10 percent
Throttle #1 Droop Percentage 0 to 10 percent
Throttle #2 Droop Percentage 0 to 10 percent
TSC1 Droop Percentage 0 to 10 percent
Engine Operating Mode #1 High Idle Speed 1500 to 2800 rpm
Engine Operating Mode #1 High Idle Droop Percentage 5 to 10 percent
Engine Operating Mode #1 Throttle #1 Droop Percentage 0 to 10 percent
Engine Operating Mode #1 TSC1 Droop Percentage 0 to 10 percent
Aftertreatment #1 DEF Tank Configuration 19 Liter Landscape

19 Liter Portrait
DEF Tank Height Parameters Various
UENR4504 49
i05870106
Customer Specified Parameters Worksheet
50 UENR4504
Table 82
Customer Specified Parameters Worksheet
Speed Control
“Low Idle Speed”
Engine Idle Shutdown Enable Status
Engine Idle Shutdown Delay Time
Engine Idle Shutdown Warning Time
PTO and Throttle Lock Parameters

“Throttle Lock Feature Installation Status”
“Multi-State Input Switch Enable Status”
“Mode Select Enable/Disable”

“Throttle Lock Engine Set Speed #1”
“Throttle Lock Increment Speed Ramp Rate”
“Throttle Lock Decrement Speed Ramp Rate”
“Throttle Lock Engine Set Speed Increment”
“Throttle Lock Maximum Engine Speed”
“Throttle Position #1 Engine Speed”
Miscellaneous
“Monitoring Mode Shutdowns”
“Limp Home Desired Engine Speed”
“Hydrocarbon Elevated Idle Speed”
“Engine Acceleration Rate”
Configurable Inputs
Air Filter Restriction Switch Installation Status

Air Filter Restriction Switch Configuration
“User Defined Switch Installation Status”

“Machine Idle Status Input Configuration”
Configurable Outputs
Oil Pressure Lamp Installation Status
Wait to Start Lamp Installation Status
Warning Lamp Installation Status
Shutdown Lamp Installation Status
Malfunction Indicator Lamp (MIL) Installation Status
DEF Level Lamp Installation Status
DEF Quality Lamp Installation Status
(continued)
UENR4504 51
(Table 82, contd)

Starter Relay Installation Status
Low Pressure Fuel Pump Installation Status
Tachometer Output Configuration (Degrees per Pulse)
Remote Torque Speed Control Enable Status
TSC1 Fault Reaction

TSC1 Fault Handling
Throttle Arbitration Method

Manual Throttle Arbitration Precondition Check
Throttle Enable Status
Throttle #1 Initial Lower Position

Throttle #1 Idle Validation Minimum OFF Threshold
Throttle #1 Idle Validation Maximum ON Threshold
Throttle #1 Lower Diagnostic Limit
Throttle #1 Upper Diagnostic Limit
Throttle #2 Initial Lower Position


Throttle #2 Idle Validation Minimum OFF Threshold
Throttle #2 Idle Validation Maximum ON Threshold
Throttle #2 Lower Diagnostic Limit
Throttle #2 Upper Diagnostic Limit
Engine Operating Mode
High Idle Speed
High Idle Droop Percentage
TSC1 Droop Percentage
Engine Operating Mode #1 High Idle Speed
Engine Operating Mode #1 High Idle Droop Percentage
Engine Operating Mode #1 Throttle #1 Droop Percentage
Engine Operating Mode #1 TSC1 Droop Percentage
(continued)
52 UENR4504
(Table 82, contd)

Aftertreatment #1 DEF Tank Configuration
DEF Tank Height Parameters
UENR4504 53
System Configuration Parameters
System Configuration
Parameters
i05870129
System Configuration
Parameters
System configuration parameters are programmed at

the factory. Normally, system configuration
parameters would never be changed through the life
of the engine. System configuration parameters must
be reprogrammed if an Electronic Control Module
(ECM) is replaced. System configuration parameters
are not reprogrammed if the ECM software is
changed. The following parameters are system
configuration parameters.
Engine Rating Information

Information regarding the engine power and speed.
Rated power
Rated Engine Speed
Peak torque
Peak Torque Speed
ECM Identification Parameters

ECU Serial Number
Application Software Part Number
Application Software ID
54 UENR4504
i05952249
Acceleration Is Poor or Throttle

Response Is Poor
Probable Causes
• Diagnostic codes
• Parameters in the Electronic Control Module
(ECM)
• Throttle Position Sensor/Throttle Switches
• Air intake and exhaust system

• Valve lash
• Turbocharger
• Fuel supply
• Low compression (cylinder pressure)
• Electronic unit injectors

• Individual malfunctioning cylinder
Recommended Actions
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
Note: The procedures have been listed in order of

probability. Complete the procedures in order.
Note: If the problem only occurs under certain

conditions, test the engine under those conditions.
Examples of certain conditions are high engine
speed, full load, and engine operating temperature.
Troubleshooting the symptoms under other
conditions can give misleading results.
UENR4504 55
Table 83
Troubleshooting Test Steps Values Results
1. Diagnostic Codes Engine Derate Result: A diagnostic code is present.

or Diagnostic
Note: Certain diagnostic codes and/or event codes may cause Codes Troubleshoot the diagnostic code. Refer to Troubleshoot-
poor performance. ing, “Diagnostic Trouble Codes”.
A. Use the electronic service tool to check for active or logged di- Result: A diagnostic code is not present.
agnostic codes. Proceed to Test Step 2.
2. Parameters in the Electronic Control Module (ECM) Parameters Result: The parameters are not correct.
A. Use the electronic service tool to verify that the correct parame- Input the correct parameters. Refer to Troubleshooting,
ters are being used. Refer to Troubleshooting, “Customer Speci- “Customer Specified Parameters” for additional
fied Parameters” for additional information. information.
Result: The parameters are correct.
Proceed to Test Step 3.
3. Throttle Position Sensor/Throttle Switches Electrical Result: The throttle response is not as expected.
connections
A. Turn the start switch to the ON position. If the maximum no-load speed cannot be obtained refer to
Troubleshooting, “Switch Circuits - Test (Throttle Switch)”
B. Run the engine until the speed is equal to the maximum no-load and Troubleshooting, “Mode Selection - Test”.
speed.
If the engine speed is erratic refer to Troubleshooting,
C. Use the electronic service tool to make sure that the throttle is “Speed Control (Analog) - Test”.
set to reach the maximum no-load speed. Refer to Troubleshoot-
ing, “Throttle Setup” Result: All responses are normal.
4. Air Intake and Exhaust System Restrictions Result: There are restrictions in the air inlet or exhaust
system.
A. Observe the engine warning lamp. Check for an air filter restric-
tion indicator, if equipped. Replace plugged air filters. Refer to the Make the necessary repairs, Refer to Systems Operation/
Operation and Maintenance Manual. Testing and Adjusting, “Air Inlet and Exhaust System - In-
spect” for additional information.
B. Check the air inlet and exhaust system for restrictions and/or
leaks. Refer to Systems Operation/Testing and Adjusting, “Air Inlet Result: There are no restrictions in the air inlet or exhaust
and Exhaust System - Inspect”. system.
5. Valve Lash Valve lash Result: The valve lash is not correct.
Note: The valve lash can affect the performance of the engine. Make any necessary repairs. Refer to Systems Operation,
A. Check the valve lash. Refer to Systems Operation, Testing and Testing and Adjusting, “Engine Valve Lash - Inspect”.
Adjusting, “Engine Valve Lash - Inspect”.
Result: The valve lash is correct.
(continued)
56 UENR4504
(Table 83, contd)

7. Turbocharger Turbocharger Result: There is a fault on the turbocharger.
Note: The turbocharger that is installed on the engine is a nonser- Repair the turbocharger or replace the turbocharger. Refer
viceable item. If any mechanical fault exists, then the faulty turbo- to Disassembly and Assembly, “Turbocharger - Remove”
charger must be replaced. and Disassembly and Assembly, “Turbocharger - Install”.
A. Ensure that the mounting bolts for the turbocharger are tight. Result: The turbocharger is OK.
B. Check that the oil drain for the turbocharger is not blocked or Proceed to Test Step 8.
restricted.
C. Check that the compressor housing for the turbocharger is free

of dirt and debris. Make sure that the housing is not damaged.
D. Check that the turbine housing for the turbocharger is free of

dirt and debris. Make sure that the housing is not damaged.
E. Check that the turbine blades rotate freely in the turbocharger.
F. Ensure that the wastegate on the turbocharger is adjusted cor-

rectly. Refer to Systems Operation, Testing, and Adjusting, “Turbo-
charger - Inspect”. If the wastegate actuator is faulty, replace the
turbocharger. Refer to Disassembly and Assembly, “Turbocharger
- Remove” and Disassembly and Assembly, “Turbocharger -
Install”.
8. Fuel Supply Fuel system Result: The fuel supply is not OK.
A. Visually check the fuel level in the fuel tank. Do not rely on the Repair the fuel system or replace the fuel system compo-
fuel gauge only. nents, as necessary.
B. Ensure that the vent in the fuel cap is not filled with debris. Result: The fuel supply is OK.
C. Ensure that the fuel supply valve (if equipped) is in the full Proceed to Test Step 9.
OPEN position.
D. If the temperature is below 0 °C (32 °F), check for solidified fuel

(wax).
E. Check the primary filter/water separator for water in the fuel.
F. Check for fuel supply lines that are restricted.
G. Check that the low-pressure fuel lines are tight and secured
properly.
H. Replace the primary and secondary fuel filters.
G. Check the diesel fuel for contamination. Refer to Systems Op-

eration, Testing, and Adjusting, “Fuel Quality - Test”.
H. Check for air in the fuel system. Refer to Systems Operation,

Testing, and Adjusting, “Air in Fuel - Test”.
I.
Ensure that the fuel system has been primed. Refer to Systems
Operation, Testing, and Adjusting, “Fuel System - Prime”.
(continued)
UENR4504 57
(Table 83, contd)

9. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside the
compression specifications.
A. Perform a compression test. Refer to Systems Operation, Test-
ing, and Adjusting, “Compression - Test”. Investigate the cause and rectify any faults.
Note: Possible causes of low compression are shown in

the following list:
· Loose glow plugs

· Faulty piston
· Faulty piston rings
· Worn cylinder bores
· Worn valves
· Faulty cylinder head gasket
· Damaged cylinder head
Result: The results of the compression test are OK.
10. Electronic Unit Injectors Diagnostic Result: There are active diagnostic codes relating to the
codes fuel injectors.
A. Use the electronic service tool to check for active diagnostic co-
des that relate to the electronic unit injectors. Troubleshoot the active diagnostic codes.
Refer to Troubleshooting, “Diagnostic Trouble Codes”.
Result: All injectors are OK.
11. Individual Malfunctioning Cylinders Cylinders Result: The test indicates a faulty cylinder.
A. With the engine speed at a fast idle, use the electronic service Investigate the cause of the fault on any cylinder that is not
tool to perform the manual “Cylinder Cut Out Test” . operating. Investigate the cause of the fault on any cylinder
that is operating below normal performance.
As each cylinder is cut out, listen for a change in the sound from
the engine. When a cylinder is cut out, there should be a notice- Result: The test indicates that all cylinders are OK.
able change in the sound of the engine.
Contact the Dealer Solution Network (DSN).
If a change in the sound of the engine is not noted, the isolated
cylinder is not operating under normal conditions. If the isolation of
a cylinder results in a change in the sound that is less noticeable,
the cylinder may be operating below normal performance.
i05952252 Probable Causes

Alternator Is Noisy • Alternator drive belt
• Alternator mounting bracket
Note: This symptom is not an electronic system fault. • Alternator drive pulley
Refer to Systems Operation, Testing and Adjusting • Alternator bearings

for information on possible electrical causes of this
condition. Recommended Actions
58 UENR4504
Table 84
1. Alternator Drive Belt and Tensioner Drive belt Result: The alternator drive belt is in good condition and
the belt tension is correct.
A. Inspect the condition of the alternator drive belt.
B. Check the belt tension.
Result: The alternator drive belts are not in good condition
Note: Excessive belt tension can result in damage to the or the belt tension is incorrect.
alternator.
If the alternator drive belts are worn or damaged, replace
the belts. Refer to Disassembly and Assembly, “Alternator
Belt - Remove and Install” for the correct procedure.
Result: The alternator drive belts are in good condition and

2. Alternator Mounting Bracket Alternator Mounting Result: The alternator mounting bracket is cracked and
Bracket distorted.
A. Inspect the alternator mounting bracket for cracks and
distortion. Repair the mounting bracket or replace the mounting
bracket.
Note: The repair/replacement will ensure that the alternator

drive belt and the alternator drive pulley are in alignment.
Result: The alternator mounting bracket is OK.
3. Alternator Drive Pulley Alternator Drive Result: There is excessive wear on the alternator drive
Pulley pulley.
A. Check the condition of the alternator drive pulley. Look for
deep grooves that have been worn into the pulley by the belt. Replace the pulley.
Check that the nut for the pulley has not become loose.
Result: The alternator drive pulley nut was loose.
Tighten the nut.
Result: There is not excessive wear on the alternator drive

pulley.
4. Alternator Bearings Alternator bearings Result: The alternator bearings are not OK.
A. Check the alternator bearings for signs of wear. Repair the alternator or replace the alternator, as needed.
Refer to Disassembly and Assembly for the correct
procedure.
Result: The alternator bearings are OK.
UENR4504 59
i05989269
Alternator Problem
(Charging Problem and/or Noisy
Operation)
Probable Causes
• Alternator
• Charging Circuit
Recommended Actions
Table 85
1. Condition of the Alternator Drive Belts Drive belt Result: The alternator drive belts are in good condition and
A. Inspect the condition of the alternator drive belts.
B. Check the belt tension. If the engine is equipped with an au-
tomatic belt tensioner, check the automatic belt tensioner. Result: The alternator drive belts are not in good condition
or the belt tension is incorrect.
Excessive belt tension can result in damage to the alternator.
If the alternator drive belts are worn or damaged, replace
the belts. Refer to Disassembly and Assembly for the cor-
rect procedure.
If necessary, replace the automatic belt tensioner. Refer to

Disassembly and Assembly for the correct procedure.
2. Condition of the Alternator Drive Pulley Alternator Drive Result: There is excessive wear on the alternator drive
Pulley pulley.
A. Check the condition of the alternator drive pulley. Look for
deep grooves that have been worn into the pulley by the belt. Replace the pulley.
Check that the nut for the pulley has not become loose.
Result: The alternator drive pulley nut was loose.
Tighten the nut.
Result: There is not excessive wear on the alternator drive

pulley.
(continued)
60 UENR4504
(Table 85, contd)

3. Wear of the Alternator Bearings Alternator bearings Result: The alternator bearings are OK.
A. Check the alternator bearings for signs of wear. Proceed to Test Step 4.
Result: The alternator bearings are not OK.
Repair the alternator or replace the alternator, as needed.

Refer to Disassembly and Assembly for the correct
procedure.
4. Operation of the Alternator or Regulator Regulator and Result: The regulator and alternator are operating properly.
alternator
A. Verify that the alternator or the regulator is operating cor- Proceed to Test Step 5.
rectly. Refer to Systems Operation, Testing and Adjusting, “Al-
ternator - Test” for the proper testing procedures. Result: The regulator and alternator are not operating
properly.
Repair the alternator and regulator or replace the alternator

and regulator, as needed. Refer to Disassembly and As-
sembly for the correct procedure.
5. Inspection of the Charging Circuit Charging circuit Result: The charging circuit is not working properly.
A. Inspect the battery cables, wiring, and connections in the Clean all connections and tighten all connections. Replace
charging circuit. any faulty parts.
i05989429
Battery Problem
Probable Causes
• Charging circuit
• Battery
• Auxiliary device
Recommended Actions
Complete the procedure in the order in which the
steps are listed.
UENR4504 61
Table 86
1. Charging Circuit Charging Result: The charging circuit is not OK.

circuit
A. Check that the battery charging circuit is operating correctly. Re- Repair the charging circuit, as necessary.
fer to Troubleshooting, “Alternator Problem”.
Result: The charging circuit is OK.
2. Battery Battery Result: The battery is not OK.
A. Verify that the battery is no longer able to hold a charge. Refer Replace the battery. Refer to the Operation and Maintenance
to Systems Operation/Testing and Adjusting, “Battery - Test”. Manual, “Battery - Replace”.
Result: The battery is OK.
3. Auxiliary Device Auxiliary Result: The battery has been drained by an auxiliary device
Device being left in the ON position.
A. Check if an auxiliary device has drained the battery by being left
in the ON position. Charge the battery. Verify that the battery is able to maintain a
charge. Refer to Systems Operation/Testing and Adjusting for
the correct procedure.
Result: The battery has not been drained by an auxiliary de-

vice being left in the ON position.
Contact the Dealer Solutions Network (DSN).
i05952261
Coolant Contains Oil

Probable Causes
• Engine oil cooler

• Cylinder head gasket
• Cylinder head
• Cylinder block
Recommended Actions
steps are listed.
62 UENR4504
Table 87
1. Engine Oil Cooler Oil Cooler Result: A leak is found in the engine oil cooler.
A. Drain the coolant from the cooling system. Drain the lubricat- Install a new oil cooler. Refer to Disassembly and Assem-
ing oil from the engine oil cooler. Refer to the Operation and bly, “Engine Oil Cooler - Remove” and Disassembly and
Maintenance Manual for more information. Assembly, “Engine Oil Cooler - Install” for the correct
procedure.
B. Check for leaks in the engine oil cooler. Refer to Systems
Operation, Testing, and Adjusting, “Cooling System” for the Flush the cooling system. Refer to the Operation and Main-
proper procedure. tenance Manual for the correct procedure. Refill the cooling
system with the correct coolant. Refer to the Operation and
Maintenance Manual for the recommended coolant and
capacities.
Refill the engine with the proper oil after the leak has been
repaired. Refer to the Operation and Maintenance Manual
for the correct oil capacities and viscosity.
Result: A leak was not found in the engine oil cooler.
2. Cylinder Head Gasket Cylinder head Result: The cylinder head gasket does not show signs of
gasket damage or leakage.
A. Remove the cylinder head. Refer to Disassembly and As-
sembly, “Cylinder Head - Remove”. Install a new cylinder head gasket and install the cylinder
head. Refer to Disassembly and Assembly, “Cylinder Head
B. Inspect the cylinder head gasket for faults and any signs of - Install” .
leakage.
Result: The cylinder head gasket shows signs of damage
or leakage.
3. Cylinder Head Cylinder head Result: A fault is found in the cylinder head.
A. Check for cracks in the cylinder head. Perform a leak test on Repair the cylinder head or replace the cylinder head. In-
the cylinder head. Refer to System Operation, Testing and Ad- stall the cylinder head. Refer to Disassembly and Assem-
justing, “Cylinder Head - Inspect” for the correct procedure. bly, “Cylinder Head - Install”.
Result: A fault is not found in the cylinder head.
4. Cylinder Block Cylinder block Result: A fault is found in the cylinder block.
A. Inspect the top face of the cylinder block for faults and signs Repair the cylinder block or replace the cylinder block. In-
of leakage. spect the top deck. Refer to the Reuse and Salvage Guide-
Refer to Systems Operation, Testing, and Adjusting, “Cylinder lines for the proper inspection procedure.
Block - Inspect” for the correct procedure.
Result: No fault is found in the cylinder block.
Install the cylinder head. Refer to Disassembly and Assem-

bly, “Cylinder Head - Install”.
Contact the Dealer Solutions Network (DSN).
UENR4504 63
i05989049
Coolant Level Is Low
Note: On engines equipped with a Diesel Exhaust

Fluid (DEF) system, the DEF tank requires coolant
flow around the tank. The coolant diverter valve will
turn the flow to the DEF tank on or off. If the coolant
system is filled when the coolant diverter valve is
CLOSED , the coolant level will drop when the
coolant diverter valve is opened. This situation does
not necessarily indicate a fault.
Inspect the cooling system for leaks. Refer to
Systems Operation, Testing and Adjusting, “Cooling
System - Test” for the correct procedure.
i05991749
Coolant Temperature Is High
This procedure covers the following diagnostic codes:

Table 88
Diagnostic Trouble Codes for High Coolant Temperature
J1939 Code Description Notes

110-15 Engine Coolant Temperature : High - least The Electronic Control Module (ECM) detects that the coolant temperature
severe (1) is greater than 110° C (230° F) for at least 0.5 seconds. The code will be
reset if the coolant temperature is less than 110° C (230° F) for at least
0.5 seconds.
If equipped, the warning lamp will come on. The ECM will log the diagnos-
tic code.
110-16 Engine Coolant Temperature : High - moder- The Electronic Control Module (ECM detects that the coolant temperature
ate severity (2) is greater than 112° C (233.6° F) for at least 0.5 seconds. The code will be
reset if the coolant temperature is less than 110° C (230° F) for at least
0.5 seconds.
If equipped, the warning lamp will flash. The ECM will log the diagnostic
code.
Probable Causes
• Coolant level
• Coolant temperature sensor
• Radiator and hoses

• Radiator cap and pressure relief valve
• Water temperature regulator

• Engine cooling fan
• Quality of coolant
• Coolant pump
64 UENR4504
Recommended Actions
Table 89
1. Diagnostic Codes Diagnostic Result: Diagnostic codes are not present.

Codes
A. Use the electronic service tool to check for diagnostic codes that Return the unit to service.
relate to the temperature in the cooling system.
Result: Diagnostic codes are present.
2. Coolant Level Engine coolant

level Result: The engine coolant level is low.
A. Check the coolant level.
Check the cooling system for leaks. Refer to Systems Op-
eration, Testing and Adjusting, “Cooling System - Test” for
additional information. Repair any leaks immediately.
Result: The engine coolant level is OK.
3. Coolant Temperature Sensor Coolant tem- Result: The temperature sensor is not accurate.
perature sensor
A. Compare the reading for the coolant temperature on the elec- Troubleshoot the circuit and the coolant temperature sen-
tronic service tool to the reading for the coolant temperature on a sor. Refer to Troubleshooting, “Sensor Signal (Analog,
calibrated test gauge. Passive) - Test”.
Result: The temperature sensor is reading accurately.
4. Radiator and Hoses Radiator and Result: The radiator fins are blocked or damaged.
hoses
A. Check the radiator fins for dirt, debris, and/or damage. Remove any dirt and/or debris and straighten any bent
fins.
B. Check for collapsed hoses and/or other restrictions.
Result: The radiator has internal blockage.
C. Check the radiator for internal blockage.
Remove the blockage.
D. Ensure that the radiator size is sufficient. An undersized radiator
does not have enough area for the effective release of heat. An un- Result: The radiator fins are not damaged and the radiator
dersized radiator may cause the engine to run at a temperature that does not have an internal blockage.
is higher than normal. The normal temperature is dependent on the
ambient temperature. Proceed to Test Step 5.
(continued)
UENR4504 65
(Table 89, contd)

5. Radiator Cap and Pressure Relief Valve Radiator cap Result: The pressure relief valve and/or the water temper-
ature regulator are not operating properly.
A. Pressure-test the cooling system. Refer to Systems Operation,
Testing, and Adjusting, “Cooling System” for the correct procedure. Clean the components or replace the components.
B. Check that the seating surfaces of the pressure relief valve and Result: The pressure relief valve and/or the water temper-
the radiator cap are clean and undamaged. ature regulator are operating properly.
C. Check operation of the pressure relief valve and/or the water Proceed to Test Step 6.
temperature regulator.
6. Water Temperature Regulator Water Temper- Result: The water temperature regulator is not operating
ature Regulator correctly.
A. Check the water temperature regulator for correct operation. Re-
fer to Systems Operation, Testing, and Adjusting, “Cooling System” Replace the water temperature regulator. Refer to Disas-
for the proper procedure. sembly and Assembly, “Water Temperature Regulator -
Result: The water temperature regulator is operating

correctly.
7. Engine Cooling Fan Fan and drive Result: The drive belt is not tensioned correctly.
belt
A. Check for a loose drive belt. Result: The fan is damaged.
Note: A loose fan drive belt will cause a reduction in the air flow Repair the fan or replace the fan, as necessary. Refer to
across the radiator. Disassembly and Assembly, “Fan - Remove and Install”.
B. Check the engine cooling fan for damage. Result: The fan is OK and the fan belt is tensioned
correctly.
8. Quality of Coolant Coolant Result: The coolant is not of an acceptable quality.
A. Check the quality of the coolant. Refer to the Operation and Drain and refill the coolant system with coolant of the cor-
Maintenance Manual, “Refill Capacities and Recommendations - rect quality. Refer to the Operation and Maintenance Man-
Coolant”. ual, “Refill Capacities and Recommendations - Coolant”.
Result: The coolant is of an acceptable quality.
(continued)
66 UENR4504
(Table 89, contd)

9. Inspection of the Coolant Pump Coolant pump Result The coolant pump is damaged or not operating
correctly.
A. Inspect the impeller of the coolant pump for damage and/or
erosion. If necessary, replace the coolant pump. Refer to Disas-
sembly and Assembly, “Water Pump - Remove” and Disas-
sembly and Assembly, “Water Pump - Install”.
Result The coolant pump is not damaged and the pump is

operating correctly.
10. Cylinder Head Gasket Cylinder Head Result: Bubbles are present in the coolant or the coolant
gasket is discolored.
Switch off the engine and allow the engine to cool to below normal
working temperature. Remove the pressure cap for the coolant sys- Check the cylinder head gasket. Refer to the recom-
tem. Start the engine and inspect the coolant for the presence of mended action for the cylinder head gasket within Trouble-
bubbles or discoloration of the coolant. shooting, “Oil Contains Coolant”.
Note: If bubbles are present in the coolant or the coolant is discol- Check the cylinder head for flatness. Refer to the recom-
ored, combustion gases may be entering the cooling system. mended action for checking flatness of the cylinder head
within Systems Operation, Testing, and Adjusting, “Cylin-
der Head - Inspect”.
Result: There is no evidence of gas leakage into the cool-

ing system.
i05952268
Coolant Temperature Is Low Personal injury can result from hot coolant, steam
and alkali.
Use this procedure in order to troubleshoot a low At operating temperature, engine coolant is hot
coolant temperature. and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Probable Causes
Remove filler cap slowly to relieve pressure only
• Thermostat when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
Cooling System Conditioner contains alkali.
• Extreme ambient temperatures Avoid contact with skin and eyes.
• Engine cooling fan configuration
Recommended Actions steps are listed.
UENR4504 67
Table 90
1. Make Sure the Engine is Correctly Equipped for Ambient Engine operation Result: The engine is equipped for the ambient
Conditions conditions.
A. Ensure that the engine is correctly equipped for the ambient Proceed to Test Step 2.
conditions.
Result: The engine is not equipped for ambient
conditions.
Refer to the OEM documentation for more information

regarding equipment required for cold-weather
operation.
2. Inspect the Cooling System Engine coolant Result: The engine coolant level is OK.
level
A. Check the coolant level. Proceed to Test Step 3.
B. Check for signs of a coolant leak. Result: The engine coolant level is not OK.
Note: If the coolant temperature sensor is not immersed in coolant, Check the cooling system for leaks. Refer to Trouble-
a false reading can occur. shooting, “Coolant Level is Low” for additional informa-
tion. Repair any leaks.
3. Faulty Coolant Temperature Sensor Faulty coolant Result The coolant temperature is as expected.
temperature
A. Check the reading of the coolant temperature on the electronic sensor A failed coolant temperature sensor has been detected.
service tool. The temperature should rise steadily as the engine is Replace the temperature sensor.
warmed. Ensure that the temperature is as expected.
Result The coolant temperature is as expected.
4. Check the Engine Coolant System Coolant Result: The coolant temperature comes up to opera-
temperature tional temperature.
A. Turn the keyswitch to the OFF position.
Return the unit to service.
B. Connect to the electronic service tool.
Result The coolant temperature does not come up to
C. Start the engine. operational levels.
D. Monitor the “Engine Coolant Temperature” in the status screen Test the . Refer to Systems Operation, Testing, and Ad-
justing, “Water Temperature Regulator - Test”. If the test
fails, replace the water temperature regulator. Refer to
Disassembly and Assembly, “Water Temperature Reg-
ulator - Remove and Install”.
If the procedure did not correct the fault, contact the

Dealer Solution Network (DSN).
i05991949
Crankcase Breather Ejects Oil
The crankcase breather includes a pressure relief

valve that prevents a build-up of excessive pressure
in the breather system.
68 UENR4504
Recommended Actions
(1) Crankcase pressure relief valve
In normal operation of the engine, the pressure relief

valve remains closed. If there is evidence of oil
staining around pressure relief valve (1), perform the
following procedure in order to diagnose the fault.
Probable Causes
• Breather filter
• Breather hoses
• Breather heater
• Excessive blow-by
UENR4504 69
Table 91
1. Breather Filter Breather filter Result: The breather element is incorrectly installed or
damaged.
A. Check that the breather element is correctly installed and that
the element is not damaged. Install a new filter element. Refer to Operation and Mainte-
nance Manual, “Engine Crankcase Breather Element -
Replace”.
B. Check for restrictions or blockages in orifice (2). Note: If a new filter element blocks before the service peri-
od is completed, the blockage can indicate a fault in the
engine.
Result: There is a restriction or blockage in orifice (2).
If necessary, replace the crankcase breather. Refer to Dis-

assembly and Assembly, “Crankcase Breather - Remove”
and refer to Disassembly and Assembly, “Crankcase
Breather - Install”
Result: The breather filter is OK.
2. Breather Hoses Breather hoses

Result: There is a restriction or blockage in one of the
A. Check the oil return hose and the breather outlet hose for restric- breather hoses.
tions or blockages.
Replace the breather hoses, as necessary.
Result: The breather hoses are OK.
3. Breather Heater 10 V to 14 V for Result: The measured voltage is less than 10 V.

step D
A. Turn the keyswitch to the OFF position. There is a fault in the wiring to the breather heater.
Less than 10 k Repair the harness or repair the harness
B. Disconnect the breather heater connector. Ohms for step
F. Result: The measured resistance is greater than 10 k
C. Turn the keyswitch to the ON position. Ohms.
D. Use a suitable multimeter to measure the voltage at the harness Replace the breather heater.
connector for the heater.
Result: All measurements are within the expected ranges.
E. Turn the keyswitch to the OFF position.
F. Use a suitable multimeter to measure the resistance of the heater
element.
4. Excessive Blow-by Blow-by Result: The fault has been rectified.
Excessive blow-by increases the flow of fumes through the breath- Return the engine to service.
er system and can cause the breather element to block. The pres-
sure relief valve may then open. Result: The fault is still present.
A. If excessive blow-by is suspected, replace the breather element. Contact the Dealer Solution Network (DSN).
Refer to the Operation and Maintenance Manual, “Engine Crank-
case Breather Element - Replace”.
B. Investigate the cause of the excessive blow-by. Refer to Trouble-

shooting, “Oil Consumption Is Excessive”.
70 UENR4504
i05991971
Cylinder Is Noisy
Probable Causes
• Fuel quality
• Valve train components
• Injectors
• Pistons
Recommended Actions
Table 92
1. Diagnostic Codes Codes Result: A diagnostic trouble code is active or logged.
A. Establish communication between the electronic service tool and Troubleshoot the active or logged codes. Refer to Trouble-
the Electronic Control Module (ECM). shooting, “Diagnostic Trouble Codes”.
B. Check for active diagnostic codes. Result: A diagnostic trouble code is not active or logged.
2. Fuel Quality Fuel Result: The fuel quality is not OK.
A. Check the fuel quality. Refer to Systems Operation, Testing, and Drain the fuel system and replace the fuel filters. Refer to
Adjusting, “Fuel Quality - Test”. the Operation and Maintenance Manual, “Fuel System Pri-
mary Filter (Water Separator) Element - Replace” and Op-
B. Refer to Operation and Maintenance Manual for information on eration and Maintenance Manual, “Fuel System Filter -
the proper characteristics of the fuel for the engine. Replace”.
Fill the fuel system with fuel that meets the standard in the
Operation and Maintenance Manual, “Fluid
Recommendations”.
Prime the fuel system. Refer to the Operation and Mainte-

nance Manual, “Fuel System - Prime”.
Verify that the procedure has eliminated the noise.
Result: The fuel quality is OK.
(continued)
UENR4504 71
(Table 92, contd)

3. Valve Train Components Valve train Result: Valve train components are damaged.
A. Check the valve lash. Refer to Troubleshooting, “Valve Lash Is Make the necessary repairs, Verify that the repair has elimi-
Excessive”. nated the noise.
B. Check for damage to valve train components. Remove the valve Result: The valve train components are not damaged.
cover from the suspect cylinders. Check the following items for
damage: Proceed to Test Step 4.
· Valve springs
· Rocker shaft
· Pushrods
· Camshaft followers
Refer to the Disassembly and Assembly for additional information.
4. Electronic Unit Injectors Diagnostic Result: There is an active diagnostic code for the injectors.
codes
A. Use the electronic service tool to check for active diagnostic co- Troubleshoot any active injector diagnostic codes. Refer to
des that relate to the electronic unit injectors. Troubleshoot any ac- Troubleshooting, “Diagnostic Trouble Codes”.
tive diagnostic codes before continuing with this procedure.
Result: There are no active diagnostic codes for the

injectors.
5. Pistons Pistons Result: One or more pistons are worn or damaged.
A. Inspect the pistons for damage and wear. Replace any worn or damaged parts.
Verify that the repair has eliminated the noise.
Result: All pistons are OK.
i05952321
DEF Concentration Is Incorrect
Use this procedure to troubleshoot the following

codes:
Note: Refer to Troubleshooting, “Service Tool
Features” for more information about service
features.
Table 93
Diagnostic Trouble Codes for DEF Concentration Is Incorrect
(continued)
72 UENR4504
(Table 93, contd)

3516-2 Aftertreatment #1 DEF Concentration : Erratic, Intermit- The Electronic Control Module (ECM) detects that the
tent, or Incorrect concentration of the Diesel Exhaust Fluid (DEF) is out-
side of the acceptable range for at least 10 minutes.
The battery voltage is at least 9 V.
The DEF tank temperature is between 20° C (68° F) and
40° C (104° F).
The DEF quality lamp will come on.
3516-14 Aftertreatment #1 DEF Concentration : Special The ECM detects that the fluid in the DEF tank is not
Instruction DEF.
The fault is detected for at least 5 minutes.
The DEF tank temperature is between 20° C (68° F) and
40° C (104° F).
The warning lamp will flash.
Follow the troubleshooting procedure in order to identify the root cause of the fault.

probability. Complete the procedure in the order in
which the steps are listed.
Table 94
Required Service Tools
Part Number Description
T400195 Test Kit (Refractometer)
Table 95
Diagnostic Active
1. Check for Diagnostic Codes Active or Logged Diagnostic or Logged codes Result: A diagnostic code is active or logged other than a
codes. 3516-2 or 3516-14 code.
A. Establish communication between the electronic service tool Troubleshoot the active or logged code.
and the Electronic Control Module (ECM). Refer to Troubleshoot-
ing, “Electronic Service Tools”, if necessary. Result: A 3516-2 or 3516-14 diagnostic code is active or
logged.
2. Check the DEF Quality DEF quality Result: DEF quality is not within the acceptable range.
standards
A. Use a T400195 Refractometer to measure the Diesel Exhaust Drain the DEF fluid from the tank. Refill the tank with DEF
Fluid (DEF) quality. that meets ISO 22241 quality standards.
Refer to Testing and Adjusting, “Diesel Exhaust Fluid Quality - Result: DEF quality is within the acceptable range.
Test” for the correct procedure.
Replace the DEF header unit. Refer to Disassembly and
Assembly.
Repeat this procedure from Test Step 1.
If the procedure did not correct the fault, contact the Dealer Solution Network (DSN).
UENR4504 73
i05892003
DEF Does Not Purge

Table 96
Diagnostic Trouble Codes for DEF Does Not Purge
J1939 Description Notes

Code
The ECM detects that the DEF pressure is greater than the acceptable range by at least
35 kPa (5 psi) after the DEF system has purged. The acceptable range is determined by
Aftertreatment 1 Diesel Exhaust Fluid
ambient conditions and DEF tank temperature.
4334-20 Doser Absolute Pressure : Data
Drifted High
The warning lamp will come on.
This diagnostic code will clear the next time the keyswitch is turned to the ON position.
The ECM detects that the DEF pressure is less than the acceptable range by at least
75 kPa (11 psi) after the DEF system has purged. The acceptable range is determined by
Aftertreatment 1 Diesel Exhaust Fluid ambient conditions and DEF tank temperature.
4334-21 Doser Absolute Pressure : Data The battery voltage is at least 10 V.
Drifted Low The warning lamp will come on.
This diagnostic code will clear the next time the keyswitch is turned to the ON position.
74 UENR4504

steps are listed.
View of the DEF pump module.
(1) DEF backflow line connector
View of the DEF tank and DEF tank header unit
UENR4504 75
Table 97
1. Check the Backflow Line for a Restriction DEF return line Result: An obstruction was found.
restriction
A. Turn the keyswitch to the OFF position for 2 minutes. Flush line with water or low-pressure air. If necessary, re-
B. Remove the backflow line from DEF tank header (2) and DEF place the line.
pump (1). Result: An obstruction was not found.
C. Inspect the backflow line for obstructions. If one of the preceding diagnostic codes are logged every
Note: Possible obstructions are ice, DEF deposits, or debris. time the engine is shut down, either the purging pump is
not operating correctly or the DEF pump pressure sensor
is faulty.
Replace the DEF pump module. Refer to Disassembly
and Assembly.
i05952343
DEF Module Does Not

Respond
Use this procedure to troubleshoot the following

codes:
Note: Refer to Troubleshooting, “Service Tool

Features” for more information about service
features.
Table 98
Diagnostic Trouble Codes for DEF Module Does Not Respond

The Electronic Control Module (ECM) detects that the DEF injector does
not open when requested.
Aftertreatment Diesel Exhaust Fluid Dosing
5394-7 The battery voltage is at least 10 V.
Valve : Not Responding Properly
There are no other active diagnostic codes for the DEF injector.
The warning lamp will flash. The engine will be derated.
Follow the troubleshooting procedure in order to identify the root cause of the problem.

probability. Complete the procedure in the order in
which the steps are listed.
76 UENR4504
Table 99
1. Check for Active Diagnostic Codes Diagnostic Result: There are other active diagnostic codes relating to
codes the DEF injector or the DEF quality.
A. Connect the electronic service tool to the diagnostic connector.
Troubleshoot the other diagnostic codes before returning
B. Turn the keyswitch to the ON position. to this procedure. Refer to Troubleshooting, “Diagnostic
Trouble Codes”.
C. Use the electronic service tool to check for active diagnostic
codes. Result: There are no other active diagnostic codes relat-
ing to the DEF injector or the DEF quality. A 5394-7 diag-
nostic code is active.
2. Perform the “ DEF Dosing System Accuracy Test”” DEF dosing Result: The quantity collected is not within the acceptable
range.
A. Perform the “DEF Dosing System Accuracy Test” . Refer to
Systems Operation, Testing and Adjusting, “Aftertreatment SCR Replace the DEF injector. Refer to Disassembly and As-
System Dosing Test” for the correct procedure. sembly, “DEF Injector and Mounting - Remove and
Install”.
Result: The quantity collected is within the desired range.
3. Check the DEF Pressure Line Pressure line Result: There is ice in the pressure line.
A. Turn the keyswitch to the OFF position for 2 minutes. Check the operation of the line heaters. Refer to Trouble-
shooting, “DEF Line Heater - Test”.
B. Visually inspect the lines for leaks or damage. Result: There are restrictions or leaks in the lines.
C. Remove the DEF pressure line between the DEF pump and the Remove the restrictions or replace the pressure line.
DEF injector. Refer to the Disassembly and Assembly, “Diesel Ex-
haust Fluid Lines - Remove and Install”. Result: There are no restrictions in the lines.
D. Check for ice, urea deposits, or debris in the DEF pressure line. Contact the Dealer Solution Network (DSN).
i05892816
DEF Pressure Does Not

Respond
These codes can become active in the following

circumstances:
• The DEF pump pressure is not stable after the
initial priming sequence.
• The DEF pump is not able to supply DEF after the
line heaters have been energized and a heating
cycle has been completed.
UENR4504 77
Table 100
Diagnostic Trouble Codes for DEF Pressure Does Not Respond

Code
The ECM detects that the DEF backflow line pressure is not responding.
The warning lamp will come on. The DEF system will purge.
The diagnostic code will be cleared when the keyswitch has been cycled
and the DEF lines have been defrosted.
Aftertreatment #1 DEF Dosing Unit Input Lines : Not
3362-7 The DEF pressure line pressure is not responding after the defrosting
Responding Properly
period.
The warning lamp will come on. The DEF system will purge.
and the fault does not reoccur.
The ECM detects that the DEF pressure does not reach 100 kPa (14.5 psi)
after ten attempts to pressurize the system.
Aftertreatment 1 Diesel Exhaust Fluid Doser Absolute The warning lamp will come on. DEF dosing will be disabled while this diag-
4334-7 nostic code is active.
Pressure : Not Responding Properly
The ECM detects that the DEF pump is unable to reduce the DEF pressure
while the system is purging.
The ECM detects that the DEF pressure is not stable during ten attempts to
pressurize the system.
Aftertreatment 1 Diesel Exhaust Fluid Doser Absolute
4334-10 The warning lamp will flash. The DEF system will be purged and the engine
Pressure : Abnormal Rate of Change
will be derated.
and the fault does not reoccur.
Illustration 26 g03713516 Illustration 27 g03713528

View of the DEF pump module View of the DEF tank and DEF tank header unit
(1) DEF backflow line connector (4) DEF backflow line connector
(2) DEF pressure line connector (5) DEF suction line connector
(3) DEF suction line connector
steps are listed.
78 UENR4504
Table 101
1. Check the Level in the DEF Tank DEF Level Result: There is not enough DEF in the DEF tank.
A. Check that there is sufficient DEF in the DEF tank. Fill the DEF tank with DEF. Refer to Operation and Main-
Note: If there is insufficient DEF in the DEF tank, the system can fill tenance Manual, “Diesel Exhaust Fluid - Fill”.
with air.
Result: The level in the DEF tank is OK.
2. Check for Diagnostic Trouble Codes Diagnostic trou- Result: One of the diagnostic codes listed in Table 100 is
ble codes active or recently logged.
A. Turn the keyswitch to the ON position. Do not start the engine.
Result: A code other than 4334-7 is active or recently
C. Check for active or recently logged diagnostic trouble codes. logged.
Troubleshoot the logged or active code. Refer to Trouble-

shooting, “Diagnostic Trouble Codes”.
3. Check the DEF Line Heaters DEF line heaters Result: The DEF line heaters are not OK.
A. Check that the DEF line heaters are working correctly. Make any necessary repairs. Refer to Troubleshooting,
Refer to Troubleshooting, “DEF Line Heater - Test”. “DEF Line Heater - Test”.
Start the engine. If the fault is still present, proceed to Test

Step 4.
Result: The DEF line heaters are OK.
(continued)
UENR4504 79
(Table 101, contd)

4. Inspect All the DEF Lines for Leaks Leaks Result: The lines are leaking, damaged, pinched, or
disconnected.
Make the necessary repairs.
C. Use the electronic service tool to perform the “DEF Dosing Sys-
tem Verification Test ” in order to pressurize the system. Result: The lines are not leaking, damaged, pinched, or
disconnected.
D. Visually inspect all DEF lines from the tank to the DEF injector.
Look for pinched, damaged, or disconnected lines. Proceed to Test Step 5.
E. Inspect the lines for leakage.
F. Turn the keyswitch to the OFF position.
Obstructions
5. Check the DEF Lines for Obstructions Result: An obstruction was found.
A. Remove the suction line from the DEF tank header (5) and DEF Flush the line or replace the line.
pump (3).
Install the pressure lines.
B. Remove the pressure line from the DEF injector and DEF pump
(2).
Result: An obstruction was not found.
C. Remove the backflow line from the DEF pump (1) and the DEF
pump header (4).
D. Inspect the lines for obstructions. Flush lines with water/low Install a replacement DEF pump module. Refer to Disas-
pressure air if necessary. sembly and Assembly.
Note: Possible obstructions are ice, DEF deposits, or debris.
80 UENR4504
i05952353
DEF Pressure Is High

Table 102
Diagnostic Trouble Codes for DEF Pressure Is High

Code
The ECM detects that the DEF pressure is greater than 750 kPa (109 psi) for at least 0.5
seconds.
Aftertreatment 1 Diesel Exhaust Fluid The battery voltage is at least 10 V.
4334-0 Doser Absolute Pressure : High - The warning lamp will flash and the engine will be derated. DEF injection is disabled while
most severe (3) this diagnostic code is active.
The diagnostic code will clear when the DEF pressure drops below 750 kPa (109 psi) for
at least 0.5 seconds.
The ECM detects that the DEF pressure has risen above 610 kPa (88 psi) and remains
above 590 kPa (86 psi) for at least 20 seconds.
Aftertreatment 1 Diesel Exhaust Fluid
The warning lamp will flash and the engine will be derated. When this diagnostic code be-
4334-16 Doser Absolute Pressure : High -
comes active, the DEF pressure will be reduced and the pressure build-up process will be-
moderate severity (2)
gin again .
The diagnostic code will clear if the DEF pressure remains below 610 kPa (88 psi) after
the DEF system has been repressurized.
UENR4504 81

steps are listed.
82 UENR4504
Table 103
1. Check the Backflow Line for a Restriction DEF return line Result: An obstruction was found.
restriction
A. Turn the keyswitch to the OFF position for 2 minutes. Flush line with water/low pressure air. If necessary, re-
place the line.
B. Remove the backflow line from DEF tank header (2) and DEF Proceed to Test Step 3.
pump (1).
Result: An obstruction was not found.
C. Inspect the backflow line for obstructions.
Note: Possible obstructions are ice, DEF deposits, or debris.
2. Check for a Restriction in the DEF Pump DEF pump Result: DEF did not flow from the DEF backflow line into
restriction the container.
A. Connect the backflow line to DEF pump (2). Place the other end
of the line into a suitable container to collect the DEF. Replace the DEF pump. Refer to the Disassembly and
Assembly manual for the correct procedure.
B. Turn the keyswitch to the ON position. Do not start the engine.
Result: DEF flowed from the backflow line into the
C. Connect to the electronic service tool. container.
D. Perform the “DEF Dosing System Verification Test” . Wait for Connect the backflow line to DEF tank header (1).
the test to complete.
If the fault is still present, contact the Dealer Solution Net-
work (DSN).
i05897537
DEF Pressure Is Low
This procedure covers the following diagnostic code:

Table 104
Diagnostic Trouble Codes for DEF Pressure Is Low

The Electronic Control Module (ECM) detects that the Diesel Exhaust Fluid
Aftertreatment 1 Diesel Exhaust Fluid Doser
(DEF) pressure has dropped below 390 kPa (57 psi) and remains below
4334-18 Absolute Pressure : Low - moderate severity
410 kPa (59 psi) for at least 40 seconds.
(2)
The ECM detects that the duty cycle of the DEF pump required to maintain
DEF pressure is too high.
Aftertreatment #1 Diesel Exhaust Fluid Pump The DEF system is not dosing.
4374-15
Motor Speed : High - least severe (1)

steps are listed.
UENR4504 83
Table 105
1. Check the DEF Gauge Gauge Result: The gauge did not move by adding or removing flu-
position id to the tank.
A. Turn the keyswitch to the ON position.
Remove the DEF tank header and check for a stuck float.
B. Check the current position of the DEF gauge.
If the float was not stuck, replace the DEF tank header. Re-
C. Clean dirt and debris from around the tank filler cap before return the unit to service.
moving the cap. Add DEF to the DEF tank.
If the float was stuck, repair the stuck float, if possible. If
D. Check for a change in the gauge position. the float cannot be repaired, replace the DEF tank header.
E. If the gauge is in the full position, drain DEF from the tank and
look for a change in the gauge position. Result: The gauge moved by adding or removing fluid to
the tank.
2. Inspect the DEF Lines for Leaks Leaks Result: A leaking or disconnected line was found.
A. Turn the keyswitch to the ON position. Do not start the engine. Repair or replace the faulty DEF line.
B. Connect to the electronic service tool. Result: A leaking or disconnected line was not found.
C. Perform the “DEF Dosing System Verification Test” to pressurize Proceed to Test Step 3.
the system. Refer to Troubleshooting, “Service Tool Features” for
more information.
D. Inspect all of the DEF lines for disconnected lines or leaks.
3. Inspect the DEF Tank Filler Cap Filler cap Result: The cap has a blockage.
A. Clean dirt and debris from around the filler cap before removing Replace the cap.
the cap. Blockages can be caused by a build-up of dirt/debris
around the filler cap. Result: A blockage was not found.
B. Remove the cap. Proceed to Test Step 4.
C. Visually inspect the DEF tank filler cap for blockages.
84 UENR4504
UENR4504 85
Table 106
4. Check for Suction Line Restrictions Restrictions Result: An obstruction was found.
A. Disconnect suction the line from DEF pump module (1) and DEF Flush the line with water or low-pressure air or replace the
tank header (2). Refer to Illustration 30 and Illustration 31 . suction line.
B. Inspect the suction line for obstructions. Proceed to Test Step 8.
Possible obstructions are ice, DEF deposits, or debris. Result: An obstruction was not found.
Install the suction line.
5. Replace the Filters and Flush the DEF Tank DEF filter Result: The DEF tank was flushed and the filters were
replaced.
A. Turn the keyswitch to the OFF position for 2 minutes.
B. Flush the DEF tank. Refer to Systems Operation, Testing and Ad-
justing, “Diesel Exhaust Fluid Tank - Flush” for the correct
procedure.
C. Replace the DEF tank header filter and DEF pump filter. Refer to
Systems Operation, Testing and Adjusting, “Diesel Exhaust Fluid
Tank - Flush” for the correct procedure.
6. Check for a Leaking DEF Injector DEF Dosing Result: The quantity of DEF collected is not within the ac-
ceptable range.
A. Perform the DEF dosing system accuracy test. Refer to Systems
Operation, Testing and Adjusting, “Aftertreatment SCR System Dos- Replace the DEF injector. Refer to Disassembly and As-
ing Test” for the correct procedure. sembly, “DEF Injector and Mounting - Remove and Install”
Result: The quantity of DEF collected is within the ex-

pected range.
Replace the DEF pump. Refer to Disassembly and Assem-

bly, “Diesel Exhaust Fluid Pump - Remove and Install”.
86 UENR4504
i05952400
DEF Tank Level Is Low

Table 107
Diagnostic Trouble Codes for DEF Tank Level Is Low

Aftertreatment 1 Diesel Exhaust Fluid Tank The DEF tank is empty.
Level : Low - most severe (3) The battery voltage is at least 10 V.
1761-1 The Emissions System Malfunction lamp is on and the warning lamp
flashes.
The engine will be derated. The engine may shut down.

steps are listed.
Table 108
1. Check the DEF Fluid Level Gauge position Result: The gauge did not move by adding DEF to the tank.
A. Turn the keyswitch to the ON position. Proceed to Test Step 2.
B. Check the current position of the DEF gauge. Result: The gauge moved by adding DEF to the tank. Turn
the keyswitch to the OFF position for 2 minutes.
C. Clean dirt and debris from around the cap before removing the
cap. Return the unit to service.
D. Add DEF to the DEF tank.
E. Check for a change in the gauge position.
UENR4504 87
Table 109
2. Check the Electrical Connection at the DEF Tank Header Electrical Result: The electrical connectors are free of corrosion and
connections are not loose.
A. Inspect electrical connector (1) to the DEF tank header. Refer
to Troubleshooting, “Electrical Connectors - Inspect”. Proceed to Test Step 3.
Check for corrosion or loose wires. Result: The electrical connections are corroded and/or
loose.
Make the necessary repairs to the connectors. Turn the key-

switch to the OFF position for 2 minutes.
3. Inspect the DEF Tank Header Proper opera- Result: The float was not operating properly.
tion of the float
A. Turn the keyswitch to the OFF position. Repair the float, if possible. If the float cannot be repaired,
replace the DEF tank header. Refer to the Disassembly and
B. Remove tank header (2) from the DEF tank. Refer to Disassem- Assembly, “Manifold (DEF Heater) - Remove and Install”.
bly and Assembly, “Manifold (DEF Heater) - Remove and Install”.
C. Inspect the DEF tank header for a stuck float.
Result: The float was operating properly.
Install a replacement DEF tank header. Refer to the Disas-

sembly and Assembly, “Manifold (DEF Heater) - Remove
and Install”.

work (DSN).
88 UENR4504
i05952419
DEF Tank Temperature Is High

Table 110
Diagnostic Trouble Codes for DEF Tank Temperature Is High

The temperature of the Diesel Exhaust Fluid (DEF) in the DEF
tank has risen above 70° C (158° F) for at least 1 second.
Catalyst Tank Temperature : High - moderate severity
3031-16 The warning lamp will flash. The engine is derated.
(2)
The diagnostic code will clear when the DEF tank temperature
is below 65° C (149° F) for at least 2 seconds.
UENR4504 89
View of the coolant diverter valve
(1) Coolant outlet connection
(2) Electrical connector
(3) Coolant inlet connection
(4) Coolant inlet connection
(5) Electrical connector
(6) Coolant outlet connection

steps are listed.
90 UENR4504
Table 111
1. Check for Associated Codes Associated code Result: An associated code is present.
A. Connect to the electronic service tool. Troubleshoot the associated code. Refer to Trouble-
shooting, “Diagnostic Trouble Codes” for the correct
B. Check for diagnostic codes relating to the DEF tank temperature procedure.
sensor, the coolant diverter valve, or high coolant temperature.
Result: An associated code is not present.
2. Check for Corrosion in the Connector to the Tank Header Corrosion Result: There is not corrosion in the connector to the
tank header or the coolant diverter valve.
A. Inspect electrical connector (2) for the coolant diverter valve. In-
spect electrical connector (5) for the DEF tank header. Refer to Proceed to Test Step 3.
Troubleshooting, “Electrical Connectors - Inspect” for further
information. Result: There is corrosion in the connector to the tank
header or the coolant diverter valve.
Repair or replace the connector. Cycle the keyswitch.
3. Check the Coolant Supply and Return Lines for Correct Correct Result: The lines are installed correctly.
Installation installation
A. Inspect coolant inlet (3) and outlet (1) lines from coolant diverter
valve. Make sure that the coolant is flowing in the correct direction. Result: The lines are not installed correctly.
Refer to Illustration 33 .
Correctly install the lines. Proceed to Test Step 5.
B. Inspect coolant inlet (4) and coolant outlet (6) . Make sure that
the coolant is flowing in the correct direction. Refer to Illustration 34
.
(continued)
UENR4504 91
(Table 111, contd)

4. Check the Coolant Diverter Valve Solenoid for Correct Temperature rise Result: The DEF tank temperature did not increase.
Operation
Connect the coolant diverter valve to the wiring harness.
B. Disconnect the wiring harness connector from coolant diverter
valve (2).
Result: The DEF tank temperature increased.
C. Turn the keyswitch to the ON position.
The coolant diverter valve is not operating correctly. Re-
D. Connect to the electronic service tool. place the coolant diverter valve. Refer to Disassembly
and Assembly, “Solenoid Valve (DEF Heater Coolant) -
E. Start the engine. Allow the engine to warm up to operating Remove and Install”.
temperature.
E. Use the electronic service tool to monitor the “DEF Tank Tem-
perature” .
C. Turn the keyswitch to the OFF position.
5. Replace the DEF DEF Result: The fault has been eliminated.
A. Drain the DEF from the tank. Return the unit to service.
B. Refill the tank with DEF that meets ISO 22241 standards. Result: The fault is still present.
92 UENR4504
i05952477
DEF Tank Temperature Is Low

Table 112
Diagnostic Trouble Code for DEF Tank Temperature Is Low

The DCU detects that the DEF tank temperature is not respond-
Aftertreatment #1 DEF Tank Temperature : Abnormal ing when the coolant diverter valve is activated.
3031-10
Rate of Change The battery voltage is at least 10 V.

steps are listed.
UENR4504 93
Table 113
Diagnostic Trou-
1. Check for Associated Diagnostic Trouble Codes ble Codes Result: An associated diagnostic trouble code is present.
A. Connect the electronic service tool to the diagnostic connector. Troubleshoot the associated code. Refer to Troubleshoot-
ing, “Diagnostic Trouble Codes”.
B. Turn the keyswitch to the ON position.
Result: Diagnostic trouble code 3031-10 is present.
C. Use the electronic service tool to check for active diagnostic co-
des relating to the coolant diverter valve or the DEF tank tempera- Proceed to Test Step 2.
ture sensor.
2. Check the Coolant Level of the Engine Coolant Level Result: The coolant level is full.
A. Determine if the engine coolant level is full. Proceed to Test Step 3.
Result:The coolant level is not full.
Add coolant to the system.
Determine the cause of low coolant. Refer to Trouble-

shooting, “Coolant Level Is Low” for additional information.
If adding coolant does not correct the fault, proceed to

Test Step 3.
3. Check the Engine Coolant Temperature Coolant Result: The coolant temperature is greater than 50° C
temperature (122° F).
A. Start the engine. Allow the engine to warm up to normal operat-
ing temperature. Proceed to Test Step 4.
B. Connect to the electronic service tool. Result: The coolant temperature is less than 50° C
(122° F).
C. Select the Status Parameters tab.
Refer to Troubleshooting, “Coolant Temperature Is Low”
D. Check the coolant temperature. for troubleshooting information.
The temperature should be greater than 50° C (122° F).
4. Check for Coolant Leaks Leaks Result: There are no leaks in the supply or return lines.
A. Check for coolant leaks in the supply and return lines to the Proceed to Test Step 5.
DEF tank header.
Result: There are leaks in the supply or return lines.
Repair the leaks and refill the coolant system.
If the fault is still present, proceed to Test Step 5.
5. Inspect the Coolant Lines for Restrictions and Obstructions

Restrictions Result: There is a restriction in a line.
A. Check for a restriction or obstruction in the coolant lines be-
tween the engine and the DEF tank header. Repair or replace the lines with the restrictions.
Result: The coolant lines are OK.

94 UENR4504
Table 114
6. Check the Electrical Connection at the DEF Tank Header Electrical Result: The electrical connector is not corroded or loose.
connections
A. Inspect electrical connector (1) for the DEF tank header. Refer Proceed to Test Step 7.
to Troubleshooting, “Electrical Connectors - Inspect” for further in-
formation. Refer to Illustration 35 . Result: The electrical connector is corroded and/or loose.
Check for corrosion or loose wires. Make the necessary repairs to the connectors. Cycle the
keyswitch.
7. Check the Coolant Diverter Valve Operation Temperature rise Result: The DEF tank temperature increased.
Note: The coolant diverter valve will only operate if the DEF tank
temperature is less than 15° C (59° F). The fault appears to be resolved.
A. Turn the keyswitch to the ON position. If the active diagnostic code returns, contact the Dealer
Solution Network (DSN).
B. Start the engine.
Result: The DEF tank temperature did not increase.
C. Connect to the electronic service tool.
Replace the coolant diverter valve .
D. Monitor the “DEF Tank Temperature” for at least 20 minutes.
Make sure that there is a gradual rise in the DEF tank
temperature.
Note: If the DEF tank temperature reaches 17° C (62.° F), the
coolant diverter valve will close.
UENR4504 95
i04079169
ECM Does Not Communicate

with Other Modules
Probable Causes
• Electrical connectors
• Electronic Control Module (ECM)

• CAN data link
Recommended Actions
diagnostic connector. If the ECM does not
communicate with the electronic service tool, refer
to Troubleshooting, “Electronic Service Tool Does
Not Communicate”.
2. Ensure that the following items are correctly
installed and undamaged. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
• P1 and P2 connectors on the ECM
• Wiring to display modules
• Wiring to other control modules
3. Verify that the CAN data link does not have an

open or short circuit. Refer to Troubleshooting,
“CAN Data Link Circuit - Test”.
i05952511
Electronic Service Tool Does

Not Communicate
Probable Causes
• Configuration of the communications adapter
• Communication adapter and/or cables

• Electrical power supply to the diagnostic connector
• Electronic service tool and related hardware

• Electrical power supply to the Electronic Control
Module (ECM)
Recommended Actions
96 UENR4504
Table 115
1. Configuration of the Communications Adapter Communications Result: The correct “Communications Interface Device”
adapter is not selected.
A. Access “Preferences” under the “Utilities” menu on the configuration
electronic service tool. Select the correct “Communications Interface Device” .
B. Check for hardware that uses the same ports as the commu- Result: The correct port is not selected for use by the com-
nications adaptor. munication adapter.
Select the correct port for use by the communication
adapter.
Note: The most commonly used port is “COM 1” .
Result: Other hardware is sharing the same port with the

communications adaptor.
Exit or close the software programs for that device.
Result: The communications adaptor is correctly

configured.
2. Electrical Connectors Electrical Result: The connectors are not correctly installed.
connectors
A. Check for correct installation of the P1 and P2ECM connec- Repair or replace the connectors, as necessary.
tors and of the connector for the electronic service tool.
Result: The connectors are OK.
3. Communication Adapter and/or Cables Comms adaptor Result: The firmware or driver files are not the most cur-
and cables rent files.
A. Check that the firmware and driver files are the most current
files for the type of communication adapter that is being used. Update the firmware or driver files to the most current files.
Verify that the correct cable is being used between the commu- Result: The cable between the communication adapter
nication adapter and the diagnostic connector. and the diagnostic connector is not correct.
B. Disconnect and then reconnect the cable that attaches the Replace the cable between the communication adapter
communication adapter to the diagnostic connector. and the diagnostic connector with the correct type.
C. Check the operating system on the laptop computer. Result: The laptop computer has a Windows operating
system.
Restart the laptop computer in order to eliminate the possi-

bility of a conflict in the software.
Result: The adaptor and cables are OK.
(continued)
UENR4504 97
(Table 115, contd)

4. Electrical Power Supply to the Diagnostic Connector Electrical power Result: Battery voltage is not present between terminals A
and B of the diagnostic connector.
A. Use a multimeter to check that battery voltage is present be-
tween terminals A and B of the diagnostic connector. Investigate the cause and repair, as necessary.
Note: If the communication adapter is not receiving power, the Result: Battery voltage is present between terminals A
LED display on the communication adapter will be off. and B of the diagnostic connector.
5. Electronic Service Tool and Related Hardware Hardware Result: The same fault occurs on a different engine.
A. Connect the electronic service tool to a different engine. Check the electronic service tool and the related hardware
for faults.
Note: This process eliminates the electronic service tool and
the related hardware as the fault. Result: The fault does not occur on a different engine.
6. Electrical Power Supply to the Electronic Control Mod- Power to ECM Result: The power supply to the ECM is incorrect.
ule (ECM)
Investigate the cause and repair, as necessary.
A. Check the power supply to the ECM. Refer to Troubleshoot-
ing, “Electrical Power Supply - Test”. Result: The power supply to the ECM is OK.
Note: If the ECM is not receiving battery voltage, the ECM will Contact the Dealer Solution Network (DSN).
not communicate.
i05873080 Recommended Actions

Engine Cranks but Does Not Note: The procedures have been listed in order of
Start
Probable Causes
Note: Wait at least 30 seconds between attempts to
start the engine. The engine will not start unless the
keyswitch has been turned to the OFF position for at
least 30 seconds.
• Ground level shutdown switch

• Visible faults
• Fuel system
• Fuel filters
• Fuel rail Pressure Relief Valve (PRV)

• Fuel pump timing
98 UENR4504
Table 116
1. Ground Level Shutdown Switch (If Equipped) Shutdown switch Result: The ground level shutdown switch has been
activated.
A. Ensure that the ground level shutdown switch has not been
activated. Deactivate the ground level shutdown switch.
Result: The ground level shutdown switch has not been

activated.
2. Diagnostic Codes Diagnostic codes Result:There are active diagnostic codes.
A. Connect the electronic service tool to the diagnostic Troubleshoot all active diagnostic codes before continuing
connector. with this procedure. Refer to Troubleshooting, “Diagnostic
Trouble Codes”.
B. Crank the engine for 30 seconds.
Result: There are no active diagnostic codes.
D. Use the electronic service tool to check for active diagnostic
codes.
3. Visible Faults Visible faults Result: Faults found during engine inspection.
A. Visually inspect the engine for the following faults: Make any repairs, as necessary.
Attempt to start the engine. If the engine will not start, pro-
·Missing components ceed to Test Step 4.
·Damaged components
·Damaged electrical cables or loose electrical cables Result: No faults found.
·Oil leaks
·Fuel leaks Proceed to Test Step 4.
B. Check for the correct levels of fuel, oil, and coolant.
C. If the ambient temperature is below 0 °C (32 °F), make sure

that the correct specification of engine oil is used.
D. Check that the battery voltage is correct.
E. Use the electronic service tool to check the average crank-

ing speed of the engine. If the cranking speed is less than 150
rpm, investigate the cause of the low cranking speed.
F. Make sure that all fuel filters are correctly installed.
G. Drain any water from the primary fuel filter/water separator.
(continued)
UENR4504 99
(Table 116, contd)

4. Air Intake and Exhaust System Defects Result: A defect was found in the air intake or exhaust
system.
A. Check the air filter restriction indicator.
Make any necessary repairs.
B. Ensure that the air filter is clean and serviceable Attempt to start the engine. If the engine will not start, pro-
ceed to Test Step 5.
C. Check the air intake and exhaust systems for the following
defects: Result: No defects found in the air intake or exhaust
systems.
· Blockages
· Restrictions Proceed to Test Step 5.
· Damage to lines or hoses
5. Fuel System Inspection Fuel System Result: A defect was found in the fuel system.
A. Check that the fuel shut-off valve is in the OPEN position. Make any necessary repairs.
Attempt to start the engine. If the engine will not start, pro-
B. If the temperature is below 0 °C (32 °F), check for solidified ceed to Test Step 6.
fuel (wax).
Result: No defects found.
C. Check for fuel supply lines that are restricted.
D. Check that the low-pressure fuel lines are correctly installed.
E. Check the pressures in the fuel system. Refer to Systems

Operation, Testing, and Adjusting, “Fuel System Pressure -
Test”
F. Check the diesel fuel for contamination. Refer to Systems

Operation, Testing, and Adjusting, “Fuel Quality - Test”.
G. Check for air in the fuel system. Refer to Systems Opera-

tion, Testing, and Adjusting, “Air in Fuel - Test”.
H. Ensure that the fuel system has been primed. Refer to Sys-
tems Operation, Testing, and Adjusting, “Fuel System - Prime”.
6. Fuel Filters Engine start Result: The engine starts.
A. Replace the primary fuel filter and the secondary fuel filter. Return the engine to service.
Refer to the Operation and Maintenance Manual, “Fuel System
Primary Filter (Water Separator) Element - Replace”. Result: The engine does not start.
B. Attempt to start the engine. Proceed to Test Step 7.
Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
100 UENR4504
View of the fuel manifold (typical example)
UENR4504 101
Table 117
7. Fuel Rail Pressure Relief Valve (PRV) Fuel in container Result: Fuel is present in the container.
A. Turn the keyswitch to the OFF position. Install a replacement fuel manifold. Refer to Disassembly
and Assembly, “Fuel Manifold (Rail) - Remove and Install”.
B. Disconnect plastic tube assembly (4) from fuel manifold (1). When the fuel manifold has been replaced, use the elec-
Refer to Disassembly and Assembly, “Fuel Manifold (Rail) - Re- tronic service tool to perform the “Rail Pressure Sensor
move and Install”. Replacement Reset” .
C. Securely seal the end of plastic tube assembly (4). Result: No fuel is present in the container.
Note: Plastic tube assembly (4) must be sealed to prevent air
ingress into the fuel system. Proceed to Test Step 8.
D. Attach a length of hose to fuel manifold (1) and secure with

a clip at position (3).
E. Place the other end of the hose into a container that is suit-
able for fuel. Ensure that the hose is secure and will not come
out of the container while the engine is running.
F. Turn the keyswitch to the ON position.
G. Crank the engine for a maximum of 30 seconds.
H. After the engine has stopped, check the container for fuel.
8. Fuel Pump Timing Fuel pump timing Result: The fuel pump timing is incorrect.
A. Check the timing of the high-pressure fuel pump. Refer to Make any necessary adjustments.
Systems Operation, Testing, and Adjusting, “Fuel Injection Tim- Attempt to start the engine. If the engine will not start, pro-
ing - Check”. ceed to Test Step 9.
Result: The fuel pump timing is OK.
9. Low Compression (Cylinder Pressure) Low compression Result: Low compression is recorded on one or more
cylinders.
A. Perform a compression test. Refer to Systems Operation,
Testing, and Adjusting, “Compression - Test”. Possible causes of low compression are shown in the fol-
lowing list:
·Loose glow plugs
·Faulty piston
·Faulty piston rings
·Worn cylinder bores
·Worn valves
·Faulty cylinder head gasket
·Damaged cylinder head
Make any repairs, as necessary.

Attempt to start the engine. If the engine will not start, con-
tact the Dealer Solution Network (DSN).
Result: No faults found.
Contact the DSN.
102 UENR4504
i05963787
Engine Does Not Crank

Probable Causes
• Battery cables and batteries
• Switches and/or circuit breakers

• Safety interlock on the application
• Starting motor solenoid or starting circuit

• Starting motor and/or flywheel ring gear
• Engine accessories and transmission

• Hydraulic lock
Recommended Repairs
steps are listed.
Table 118
1. Battery Cables and Batteries Batteries and Result: The batteries and cables are not OK.
cables
A. Inspect the main power switch, battery posts, and battery ca- Make the necessary repairs.
bles for loose connections and for corrosion. If the battery cables
are corroded, remove the battery cables and clean the battery Result: The batteries and cables are OK.
cables. Tighten any loose connections.
B. Inspect the batteries.
C. Charge the batteries.
Test the batteries. Refer to Systems Operation, Testing and Ad-

justing, “Battery - Test”.
2. Switches and/or Circuit Breakers Switches and/or Result: The switches and/or circuit breakers are not OK.
circuit breakers
A. Check any switches and/or circuit breakers that may interfere Make the necessary repairs.
with the engine cranking. Refer to the applications electrical
schematic for additional information. Result: The switches and/or circuit breakers are OK.
(continued)
UENR4504 103
(Table 118, contd)

3. Safety Interlock on the Application Safety interlocks Result: A safety interlock is preventing the engine from
starting.
A. Check that any safety interlock features on the application
are in the safe position. Refer to the OEM documentation for de- Disengage the safety interlock if it is safe to do so. If neces-
tails of any safety interlocks on the application. sary, repair the safety interlock.
Result: There are no safety interlocks preventing the en-

gine from starting.
4. Starting Motor Solenoid and Starting Circuit Starting motor Result: The starting motor solenoid and circuit are not OK.
solenoid and
A. Test the operation of the starting motor circuit. Refer to Sys- circuit Make the necessary repairs.
tems Operation/Testing and Adjusting, “Electric Starting System
- Test”. Result: The starting motor solenoid and circuit are OK.
5. Starting Motor and/or Flywheel Ring Gear Starter pinion and Result: The starter pinion and flywheel ring gear are not
flywheel ring gear OK.
A. Test the operation of the starting motor. are OK
B. Check the wiring for the starting motor. Refer to Systems Op-
eration, Testing, and Adjusting, “Electric Starting System - Test”. Result: The starting motor and flywheel ring gear are OK.
C. Check the pinion clearance. Inspect the pinion and the fly- Proceed to Test Step 6.
wheel ring gear for damage. Refer to Systems Operation/Testing
and Adjusting, “Electrical System” for additional information.
(continued)
104 UENR4504
(Table 118, contd)

6. Engine Accessories and Transmission Engine accesso- Result: The engine accessories and transmission are not
ries and OK.
A. Ensure free movement of the driveline. transmission
B. Remove and inspect any engine accessories that may lock
up the engine. Result: The engine accessories and transmission are OK.
The following list contains examples of engine accessories that Proceed to Test Step 7.
may lock up the engine:
· Hydraulic pump that is driven from the rear gear group

· Air compressor
· Engine oil pump
· Other components that are driven by the engine
7. Hydraulic Lock Hydraulic lock Result: The engine has a hydraulic lock.
Note: If an injector has been replaced, evacuate any fluids from Make the necessary repairs.
the cylinder and attempt to start the engine. Fuel will flow from
the cylinder head into the cylinders when a unit injector is Result: The engine rotates freely.
removed.
A. Check for fluid in the cylinders by removing the individual unit
injectors. Check for damaged seals.
B. If there was excessive fuel in the cylinder, replace the seals

and reinstall the injector. Drain any excess fuel from the cylinder
head.
C. If a mechanical problem is suspected, disassemble the en-

gine. Refer to the Disassembly and Assembly manual. Inspect
the internal components for the following conditions:
· Seizure
· Broken components
· Bent components

Engine Has Early Wear Note: The procedures have been listed in order of
Probable Causes
• Contaminated oil
• Leaks in air intake system

• Engine History
• Low oil pressure

• Dirt in engine oil
• Incorrect oil
• Dirt in fuel
UENR4504 105
Table 119
1. Contaminated Oil Oil contains fuel Result: The engine oil is contaminated with fuel.
A. Check an oil sample for contamination with fuel. Refer to Trou- Investigate the cause. Refer to Troubleshooting, “Oil Con-
bleshooting, “Oil Contains Fuel”. tains Fuel”.
Result: The engine oil is not contaminated with fuel.
2. Leaks in Air Intake System Leaks in Air In- Result: Leaks found in air intake system.
take System
A leak in the air intake system may allow unfiltered air into the Repair any leaks.
engine.
Result: The air intake system is OK.
A. Inspect the air intake system for streaks which may indicate a
leakage of unfiltered air. Inspect all of the gaskets and the connec- Proceed to Test Step 3.
tions. Refer to Systems Operation, Testing, and Adjusting, “Air Inlet
and Exhaust System”.
3. Engine History Maintenance Result: The engine is not correctly maintained.

intervals
Make sure that the engine is maintained at the correct
A. Check that the engine has been serviced to the correct mainte- maintenance intervals. Refer to the Operation and Mainte-
nance intervals. Refer to Operation and Maintenance Manual, nance Manual, “Maintenance Interval Schedule”.
“Maintenance Interval Schedule”
Result: The engine is correctly maintained.
B. Check the engine history for frequent starting and stopping in
cold conditions. Proceed to Test Step 4.
Note: Frequent starting and stopping of the engine can cause

early wear. Also, operation of the engine for short periods of time in
cold conditions can cause early wear.
4. Low Oil Pressure Low oil pressure Result: The engine has a history of low oil pressure. Refer
to Troubleshooting, “Oil Pressure Is Low”.
A. Check for frequently logged diagnostic codes relating to low oil Result: There are no logged diagnostic codes for low oil
pressure. pressure.
5. Dirt in Engine Oil Dirt in engine oil Result: The engine oil shows signs of dirt or debris
A. Check the engine oil for dirt or debris. Drain the oil from the crankcase and refill the crankcase
with clean engine oil. Install new engine oil filters. Refer to
the Operation and Maintenance Manual for more
information.
Result: The engine oil is clean.
(continued)
106 UENR4504
(Table 119, contd)

6. Incorrect Oil Oil specification Result: The oil specification is incorrect.
A. Check that the engine is filled with oil of the correct specification. Drain the engine oil system and refill the engine oil sys-
Refer to the Operation and Maintenance Manual, “Refill Capacities tem. Refer to Operation and Maintenance Manual, “En-
and Recommendations”. gine Oil and Filter - Change”.
Result: The oil specification is correct.
7. Dirt in Fuel Fuel and fuel Result: The fuel has contamination.
filters
A. Remove the fuel filters. Inspect the fuel filters for contamination. Determine the cause of any contamination and make the
necessary repairs.
Note: Contaminants in the fuel such as hydrogen sulfide and sulfur
can lead to the formation of acids in the crankcase. Install new fuel filters. Refer to the Operation and Mainte-
nance Manual.
B. Obtain a fuel analysis.
Result: The fuel is not contaminated.
i06003770
Engine Has Mechanical Noise

(Knock)
Probable Causes
• Electrical connections
• Fuel quality
• Correct lubrication
• Engine accessories
• Gear train and lower end components

• Crankshaft
Recommended Actions
UENR4504 107
Table 120
1. Diagnostic Codes Diagnostic Result: There are active codes.

codes
A. Establish communication between the electronic service tool Troubleshoot any active codes before continuing with this
and the Electronic Control Module (ECM). Refer to Troubleshoot- procedure.
ing, “Electronic Service Tools”, if necessary.
Result: There are no active codes.
2. Electrical Connections Connectors Result: There are suspect connectors.
A. Check for the correct installation of the ECM P1 and P2 connec- Repair connectors that are suspect or replace connectors
tors. Check for correct installation of the fuel injector connectors. that are suspect.
Perform the “Wiggle Test” on the electronic service tool
Result: There are no suspect connectors.
A. Obtain a fuel analysis in order to confirm that the correct fuel is Note: Refer to Operation and Maintenance Manual for infor-
being used for the engine. Refer to Systems Operation/Testing and mation on the proper characteristics of the fuel for the engine.
Adjusting, “Fuel System Quality Test” for the proper procedure. If necessary,
Replace the fuel. Verify that the repair eliminated the noise.
4. Correct Lubrication Lubrication Result: The oil passages are blocked or the engine does not
have correct lubrication.
A. Check for correct lubrication of the valve components. Check for
sufficient lubrication between the injector tappets and the rocker Make the necessary repairs, Verify that the repair eliminated
arms. the noise.
B. Check for blocked oil passages. Oil passages must be clean. Result: The oil passages are not blocked and the engine has
Clean any oil passages that are questionable. Refer to the Disas- proper lubrication.
sembly and Assembly for additional information.
C. Inspect the engine oil filters for ferrous material.
D. Obtain an S-O-S oil analysis. The analysis will contribute to a

better understanding of oil contamination and the origin of the
contamination.
(continued)
108 UENR4504
(Table 120, contd)

5. Engine Accessories Engine Result An engine accessory is the source of the noise.
accessory
A. Attempt to isolate the source of the noise. Repair the engine accessory and/or replace the engine ac-
cessory, as necessary.
Result An engine accessory is not the source of the noise.
6. Valve Train Components Valve train Result: The valve train components are damaged.
A. Check the valve lash. Refer to Systems Operation, Testing, and Make the necessary repairs, Verify that the repair eliminated
Adjusting, “Valve Lash - Inspect/Adjust”. the noise.
B. Check for damage to valve train components. Remove the valve Result: The valve train components are not damaged.
cover. Check the following items for damage:
· Camshaft
· Valve springs
· Camshaft followers
· Rocker shaft
· Pushrods
C. Check for valves that do not move freely. If necessary, remove

the cylinder head and inspect the valves.
7. Gear Train and Components of the Lower End Gear train Result: The gear train or lower end components are
damaged.
A. Inspect the gear train and lower end components.
Replace any damaged parts.
Result: The gear train or lower end components are not

damaged.
8. Crankshaft Crankshaft Result: The crankshaft or the related components are dam-
aged or worn.
A. Inspect the crankshaft and the related components. Look for
worn thrust plates and wear on the crankshaft. Repair or replace any damaged parts. Verify that the repair
eliminated the noise.
B. Inspect the connecting rod bearings and the bearing surfaces
on the crankshaft. Make sure that the bearings are in the correct Result: The crankshaft or the related components are not
position. damaged or worn.
UENR4504 109
i05873118
Engine Misfires, Runs Rough

or Is Unstable
Note: If the fault is intermittent and the fault cannot be

duplicated, refer to Troubleshooting, “Power Is
Intermittently Low or Power Cutout Is Intermittent”.
Note: If the fault only occurs under certain conditions,

test the engine under those conditions. Examples of
certain conditions are high rpm, full load, and engine
operating temperature. Troubleshooting the
symptoms under other conditions can give misleading
results.
Probable Causes
• Air Intake and Exhaust System
• Fuel System Inspection
• Throttle Position Sensor/Throttle Switches

• High-pressure fuel pump

Recommended Actions
110 UENR4504
Table 121
1. Diagnostic Codes Diagnostic Result: There are active codes.

codes
and the Electronic Control Module (ECM). Refer to Troubleshoot- procedure.
Result: There are no active codes.
2. Air Intake and Exhaust System Fuel System Result: A defect was found in the air intake or exhaust
system.
B. Ensure that the air filter is clean and serviceable
Result: No defects found in the air intake or exhaust
C. Check the air intake and exhaust systems for the following systems.
defects:
· Blockages
· Restrictions
3. Fuel System Inspection Fuel supply Result: A defect was found in the fuel system.
B. If the temperature is below 0 °C (32 °F), check for solidified fuel Result: No defects found.
(wax).
E. Check the pressures in the fuel system. Refer to Systems Oper-

ation, Testing, and Adjusting, “Fuel System Pressure - Test”
F. Check the diesel fuel for contamination. Refer to Systems Oper-

ation, Testing, and Adjusting, “Fuel Quality - Test”.
G. Check for air in the fuel system. Refer to Systems Operation,

H. Ensure that the fuel system has been primed. Refer to Systems
(continued)
UENR4504 111
(Table 121, contd)

4. Throttle Position Sensor/Throttle Switches (if equipped) Electrical Result: The throttle response is not as expected.
connections
A. Turn the start switch to the ON position. If the maximum no-load speed cannot be obtained refer to
Troubleshooting, “Switch Circuits - Test (Throttle Switch)”
B. Run the engine until the speed is equal to the maximum no-load and Troubleshooting, “Mode Selection - Test”.
speed.
If the engine speed is erratic refer to Troubleshooting,
C. Use the electronic service tool to make sure that the throttle is “Speed Control - Test”.
set to reach the maximum no-load speed.
Result: All responses are normal.
5. High-Pressure Fuel Pump HP fuel pump Result: There are diagnostic codes associated with the
high-pressure fuel pump.
Note: The fuel injection pump that is installed by the factory is a
nonserviceable item. If any fault occurs within the fuel injection Diagnose the codes. Refer to Troubleshooting, “Diagnostic
pump, the fuel injection pump must be replaced. Trouble Codes”.
A. Use the electronic service tool to select the correct screen in or- If necessary, replace the high-pressure fuel pump.
der to display any diagnostic trouble codes that relate to the fuel in-
jection pump. Result: The high-pressure fuel pump is OK.
6. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside
compression the specifications.
ing, and Adjusting, “Compression - Test”. Investigate the cause and rectify any faults.
Note: Possible causes of low compression are shown in

the following list:
· Loose glow plugs

· Faulty piston
· Worn valves
(continued)
112 UENR4504
(Table 121, contd)

7. Electronic Unit Injectors Diagnostic Result: There are active diagnostic codes relating to the
codes fuel injectors.
des that relate to the electronic unit injectors. Troubleshoot any active diagnostic codes associated with
the fuel injectors. Refer to Troubleshooting, “Diagnostic
Trouble Codes”
8. Individual Malfunctioning Cylinders Cylinders Result: There is not a noticeable change in the sound of
the engine for at least one cylinder.
A. With the engine speed at a fast idle, use the electronic service
tool to perform the manual “Cylinder Cut Out Test” . As each cylin- Investigate the cause of the fault on any cylinder that is not
der is cut out, listen for a change in the sound from the engine. operating. Investigate the cause of the fault on any cylin-
When a cylinder is cut out, there should be a noticeable change in der that is operating below normal performance.
the sound of the engine.
Result: There is a noticeable change in the sound of the
engine for each cylinder.
i05271038
Engine Overspeeds

Table 122
Diagnostic Trouble Codes for the Engine Pressure Sensors

Code
190-15 Engine Speed : High - The Electronic Control Module (ECM) detects that the engine speed has exceeded 3100 rpm for at least
least severe (1) 5 seconds.
If equipped, the warning lamp will flash.
The Electronic Control Module (ECM) limits the flow If the engine speed exceeds the maximum rpm, the
of fuel in order to prevent the engine speed from ECM illuminates the warning lamp and an engine
exceeding the maximum rpm. When the engine overspeed diagnostic code is logged. No
speed has dropped to less than the maximum rpm, troubleshooting is required.
the engine overspeed diagnostic code will be reset.
The history of engine overspeeds can be viewed on
The following operating conditions can cause the the electronic service tool.
engine speed to exceed this value:
i06003891
• On a mobile machine, an incorrect transmission
gear is selected.
Engine Shutdown Occurs
• Use of an incorrect fuel Intermittently
• Combustible gases in the air inlet for the engine
Note: Use this procedure only if the engine shuts

down completely and the engine must be restarted.
UENR4504 113
Probable Causes
• Air Intake
• Fuel supply
• Switches
Recommended Actions
Table 123
1. Diagnostic Codes Codes Result: There are active codes.
Note: Certain diagnostic codes and/or event codes may cause Troubleshoot any active codes before continuing with this pro-
an engine shutdown. cedure. Refer to Troubleshooting, “Diagnostic Trouble Codes”
A. Connect the electronic service tool and check for active codes Result: There are no active codes.
and for logged codes.
2. Air Intake Blockages or Result: Blockages or restrictions found.

restrictions
A. Check the air filter for blockages or restrictions. Make any repairs, as necessary.
B. Check the air intake duct for blockages or restrictions. Result: The air intake system is OK.
3. Electrical Connectors Connectors Result: There are suspect connectors.
A. Check for the correct installation of the ECM J1/P1 and the J2/ Repair connectors that are suspect or replace connectors that
P2 connectors. Check for correct installation of the fuel injector are suspect.
connectors.
Result: There are no suspect connectors.
(continued)
114 UENR4504
(Table 123, contd)

B. If the temperature is below 0 °C (32 °F), check for solidified Result: No defects found.
fuel (wax).
E. Check the pressures in the fuel system. Refer to Systems Op-

eration, Testing, and Adjusting, “Fuel System Pressure - Test”
F. Check the diesel fuel for contamination. Refer to Systems Op-

eration, Testing, and Adjusting, “Fuel Quality - Test”.

tems Operation, Testing, and Adjusting, “Fuel System - Prime”.
5. Switches Switches Result: The shutdown switches and wiring are not OK.
A. Check the keyswitch input to the ECM. Make the necessary repairs, Verify that the repair eliminated
the fault.
B. Check any engine shutdown switches and associated wiring.
Result: The shutdown switches and wiring are OK.
i05953952
Engine Speed Does Not

Change
Note: Use this procedure only if the engine speed

does not change. This fault will not occur in an
application that operates at a constant engine speed.
Examples of these applications are generator sets
and pumps.
Probable Causes
• Multi-position throttle switch (if equipped)

• Throttle position sensor
Recommended Repairs
UENR4504 115
Table 124
1. Diagnostic Codes Codes Result: There are active diagnostic codes.
and the Electronic Control Module (ECM). Refer to Troubleshoot- procedure. Refer to Troubleshooting, “Diagnostic Trouble
ing, “Electronic Service Tools”, if necessary. Codes”
B. Use the electronic service tool to check for active or recently Result: There are no active codes.
logged diagnostic codes.
2. Multi-position Throttle Switch (If Equipped) Throttle Result: The multi-position throttle switch is faulty.
Switch
Note: When the engine is operating and the fault occurs, the con- Repair or replace the multi-position throttle switch.
figuration of the throttle will not change. Check the configuration of
the throttle only if the engine has never run. Result: The multi-position throttle switch is OK.
A. Troubleshoot the multi-position throttle switch. Refer to Trouble- Proceed to Test Step 3.
shooting, “Switch Circuits - Test (Throttle Switch)”.
3. Throttle Position Sensor Throttle posi- Result: The throttle position sensor or the associated wiring
tion sensor is faulty.
A. If a fault is suspected in the throttle sensor, refer to Troubleshoot- faults
ing, “Speed Control (Analog) - Test”. Repair or replace the throttle position sensor or the associ-
ated wiring.
Result: The throttle position sensor and the associated wir-

ing are OK.
i06026899
Engine Stalls at Low RPM

Probable Causes
• Accessory equipment
• Fuel system inspection

Recommended Actions
116 UENR4504
Table 125
1. Diagnostic Codes Diagnostic Result: A code is active or logged.

code
A. Establish communication between the electronic service tool and Troubleshoot any codes before continuing with this
the Electronic Control Module (ECM) . Refer to Troubleshooting, procedure.
“Electronic Service Tools”, if necessary.
Result: A code is not active or logged.
B. Check if any codes are active or logged.
2. Accessory Equipment Accessories Result: An engine accessory is creating an excessive

load.
A. Check all accessory equipment for faults that may create exces-
sive load on the engine. Repair or replace the engine accessory.
Result: An engine accessory is not creating an excessive

load.
(wax).
E. Check the pressures in the fuel system. Refer to Systems Opera-

tion, Testing, and Adjusting, “Fuel System Pressure - Test”
F. Check the diesel fuel for contamination. Refer to Systems Opera-

tion, Testing, and Adjusting, “Fuel Quality - Test”.

(continued)
UENR4504 117
(Table 125, contd)

4. Low Compression (Cylinder Pressure) Low Result: Low compression is recorded on one or more
compression cylinders.
A. Perform a compression test. Refer to Systems Operation, Testing,
and Adjusting, “Compression - Test”. Possible causes of low compression are shown in the fol-
lowing list:
·Loose glow plugs
·Faulty piston
·Worn valves
5. Electronic Unit Injectors Diagnostic Result: There are active diagnostic codes for the fuel
codes injectors
des that relate to the fuel injectors. Troubleshoot the active diagnostic codes. Refer to Trou-
bleshooting, “Diagnostic Trouble Codes”

Engine Top Speed Is Not Note: The procedures have been listed in order of
Obtained
Note: If this fault occurs only under load, refer to

Troubleshooting, “Acceleration Is Poor or Throttle
Response Is Poor”.
Probable Causes

• ECM parameters
• Throttle signal from the throttle position sensor

• Fuel filters
• Individual malfunctioning cylinders
118 UENR4504
Table 126
1. Diagnostic Codes Diagnostic Result: There are active or logged codes.

codes
A. Establish communication between the electronic service Troubleshoot any codes before continuing with this procedure.
tool and the Electronic Control Module (ECM). Refer to Trou-
bleshooting, “Electronic Service Tools”, if necessary. Result: There are no active or logged codes.
2. Engine Accessories and Transmission Engine accesso- Result: The engine accessories and transmission are not OK.
ries and
A. Check that the engine accessories and transmission are transmission Make the necessary repairs.
operating correctly.
Result: The engine accessories and transmission are OK.
B. Remove and inspect any engine accessories that may be
adding unexpected load to the engine. Proceed to Test Step 3.
3. ECM Parameters Parameters Result: The parameters are not configured correctly.
A. Use the electronic service tool to verify that the correct en- Correctly configure the parameters.
gine parameters are being used. Refer to Troubleshooting,
“Configuration Parameters” for additional information. Verify that the configuration change eliminated the fault.
Result: The parameters are configured correctly.
4. Throttle Signal From the Throttle Position Sensor (if Throttle position Result: The throttle position sensor or the associated wiring is
equipped) sensor faults faulty.
A. If a fault is suspected in the throttle sensor, refer to Trouble- Repair or replace the throttle position sensor or the associated
shooting, “Speed Control - Test”. wiring.
Result: The throttle position sensor and the associated wiring

are OK.
5. Air Intake and Exhaust System Restrictions Result: The air filter is plugged.
A. Check the air filter restriction indicator, if equipped. Clean Clean or replace the air filter. Refer to the Operation and Main-
plugged air filters or replace plugged air filters. Refer to the tenance Manual for further information.
Operation and Maintenance Manual.
Result: There are restrictions in the air inlet or exhaust
B. Check the air inlet and exhaust system for restrictions and/ system.
or leaks. Refer to Systems Operation, Testing and Adjusting,
“Air Inlet and Exhaust System - Inspect”. Make the necessary repairs, Verify that the repair eliminated
the fault.
Result: There are no restrictions in the air inlet or exhaust

system.
(continued)
UENR4504 119
(Table 126, contd)

fuel (wax).
D. Check that the low-pressure fuel lines are correctly

installed.

Test”


tems Operation, Testing, and Adjusting, “Fuel System -
Prime”.
7. Fuel Filters Top speed Result: The engine reaches top speed.
Refer to the Operation and Maintenance Manual, “Fuel Sys-
tem Primary Filter (Water Separator) Element - Replace”. Result: The engine does not reach top speed.
B. Run the engine at top speed. Proceed to Test Step 8.
(continued)
120 UENR4504
(Table 126, contd)

Testing, and Adjusting, “Compression - Test”. Possible causes of low compression are shown in the following
list:
·Loose glow plugs
·Faulty piston
·Worn valves
9. Individual Malfunctioning Cylinders Cylinders Result: There is not a noticeable change in the sound of the
engine for at least one cylinder.
A. With the engine speed at a fast idle, use the electronic serv-
ice tool to perform the manual “Cylinder Cut Out Test” . As Investigate the cause of the fault on any cylinder that is not op-
each cylinder is cut out, listen for a change in the sound from erating. Investigate the cause of the fault on any cylinder that
the engine. When a cylinder is cut out, there should be a no- is operating below normal performance.
ticeable change in the sound of the engine.
Result: There is a noticeable change in the sound of the en-
gine for each cylinder.
i05955206
Engine Vibration Is Excessive
Refer to Systems Operation, Testing, and Adjusting

for additional information on determining the cause of
this condition.
Probable Causes
• Engine supports
• Driven equipment

Recommended Actions
Note: Complete the procedure in the order in which
the steps are listed.
UENR4504 121
Table 127
1. Engine Supports Engine Result: The mounts and brackets are loose and/or broken.
supports
A. Inspect the mounts and the brackets while you run the engine Replace the mounts and brackets that are loose and/or
through the speed range. Look for mounts and brackets that are broken.
loose and/or broken.
Result: The mounts and brackets are not loose and/or
B. Check the alignment of the following before operating the engine broken.
under load for any length of time:
· Mounts
· Coupling
2. Driven Equipment Driven Result The driven equipment and the alignment are not
equipment OK.
A. Inspect the mounting bolts for the driven equipment. Inspect the
alignment and the balance of the driven equipment. Repair or replace the driven equipment.
B. Inspect the coupling. Result: The driven equipment and the alignment are OK.
ing, and Adjusting, “Compression - Test”. Possible causes of low compression are shown in the fol-
lowing list:
·Loose glow plugs
·Faulty piston
·Worn valves
(continued)
122 UENR4504
(Table 127, contd)

codes injectors
des that relate to the electronic unit injectors. Troubleshoot the active diagnostic codes. Refer to Trouble-
shooting, “Diagnostic Trouble Codes”
Result: There are no active diagnostic codes for the fuel

injectors.
5. Individual Malfunctioning Cylinders Cylinders Result: There is not a noticeable change in the sound of
the engine for at least one cylinder.
tool to perform the manual “Cylinder Cut Out Test” . As each cylin- Investigate the cause of the fault on any cylinder that is not
der is cut out, listen for a change in the sound from the engine. operating. Investigate the cause of the fault on any cylinder
When a cylinder is cut out, there should be a noticeable change in that is operating below normal performance.
Result: There is a noticeable change in the sound of the
engine for each cylinder.
i05874028
Exhaust Has Excessive Black

Smoke
If excessive black smoke is caused by a fault in the

engine, the Selective Catalytic Reduction (SCR)
catalyst will allow some smoke to be visible. This
condition does not mean that the SCR has failed.
Probable Causes
• Parameters in the Electronic Control Module
(ECM)
• Air intake system or exhaust system
• Valve lash
• Turbocharger

Recommended Actions
Note: Complete the procedure in the order in which
the steps are listed.
UENR4504 123
Table 128
1. Diagnostic Codes Engine Derate Result: A diagnostic code is present.

or Diagnostic
Note: Certain diagnostic codes and/or event codes may cause Codes Troubleshoot the code. Refer to Troubleshooting, “Diagnostic
poor performance. Refer to in the electronic service tool. Trouble Codes”
A. Use the electronic service tool to check for active or logged Result: A diagnostic code is not present.
codes. Proceed to Test Step 2.
2. Parameters in the Electronic Control Module (ECM) Parameters Result: The parameters are not correct.
A. Use the electronic service tool to verify that the correct pa- Input the correct parameters. Refer to Troubleshooting, “Cus-
rameters are being used. Refer to Troubleshooting, “Customer tomer Specified Parameters” for additional information.
Specified Parameters” for additional information.
Result: The parameters are correct.
3. Air Intake and Exhaust System Restrictions Result: There are restrictions in the air inlet or exhaust
system.
A. Check the air filter restriction indicator, if equipped. Replace
a plugged air filters. Refer to the Operation and Maintenance Make the necessary repairs, Refer to Systems Operation/
Manual. Testing and Adjusting, “Air Inlet and Exhaust System - In-
spect” for additional information.
B. Check the air inlet and exhaust system for restrictions and/
or leaks. Refer to Systems Operation, Testing and Adjusting, Result: There are no restrictions in the air inlet or exhaust
“Air Inlet and Exhaust System - Inspect” system.
4. Valve Lash Valve lash Result: The valve lash is not correct.
A. Check the valve lash. Refer to Systems Operation, Testing, Make any necessary repairs.
and Adjusting, “Engine Valve Lash - Inspect”.
(continued)
124 UENR4504
(Table 128, contd)

5. Turbocharger Turbocharger Result: There is a fault on the turbocharger.
Note: The turbocharger that is installed on the engine is a non- Repair the turbocharger or replace the turbocharger. Refer to
serviceable item. If any mechanical fault exists, then the faulty Disassembly and Assembly, “Turbocharger - Remove” and
turbocharger must be replaced. Disassembly and Assembly, “Turbocharger - Install”.
A. Ensure that the mounting bolts for the turbocharger are tight. Result: The turbocharger is OK.
B. Check that the oil drain for the turbocharger is not blocked Proceed to Test Step 6.
or restricted.
C. Check that the compressor housing for the turbocharger is

free of dirt and debris. Make sure that the housing is not
damaged.
D. Check that the turbine housing for the turbocharger is free of

dirt and debris. Make sure that the housing is not damaged.
E. Check that the turbine blades rotate freely in the

turbocharger.
F. Ensure that the wastegate on the turbocharger is adjusted

correctly. Refer to Systems Operation, Testing, and Adjusting,
“Turbocharger - Inspect”. If the wastegate actuator is faulty, re-
place the turbocharger. Refer to Disassembly and Assembly,
“Turbocharger - Remove” and Disassembly and Assembly,
“Turbocharger - Install”.
Testing, and Adjusting, “Compression - Test”. Possible causes of low compression are shown in the follow-
ing list:
·Loose glow plugs
·Faulty piston
·Worn valves
(continued)
UENR4504 125
(Table 128, contd)

codes injectors
A. Use the electronic service tool to check for active diagnostic
codes that relate to the electronic unit injectors. Troubleshoot the active diagnostic codes. Refer to Trouble-
shooting, “Diagnostic Trouble Codes”
Result: There are no active diagnostic codes for the fuel

injectors.
8. Individual Malfunctioning Cylinders Cylinders Result: There is not a noticeable change in the sound of the
engine for at least one cylinder.
A. With the engine speed at a fast idle, use the electronic serv-
ice tool to perform the manual “Cylinder Cut Out Test” . As Investigate the cause of the fault on any cylinder that is not
each cylinder is cut out, listen for a change in the sound from operating. Investigate the cause of the fault on any cylinder
the engine. When a cylinder is cut out, there should be a no- that is operating below normal performance.
ticeable change in the sound of the engine.
Result: There is a noticeable change in the sound of the en-
gine for each cylinder.

Exhaust Has Excessive White Diagnostic Codes
Smoke Note: The procedures have been listed in order of
Note: Some white smoke may be present during cold
start-up conditions and during acceleration after a
prolonged period at low idle. If the white smoke
persists, there may be a fault.
Probable Causes
• ECM Flash file

• Starting aids
• Coolant temperature
• Cooling system
• Fuel quality
• Valve lash

126 UENR4504
Table 129
1. Diagnostic Codes Diagnostic codes Result: There are active diagnostic codes.
A. Establish communication between the electronic service tool Troubleshoot any active codes before continuing with
and the Electronic Control Module (ECM) . Refer to Troubleshoot- this procedure. Refer to Troubleshooting, “Diagnostic
ing, “Electronic Service Tools”, if necessary. Trouble Codes”.
B. Use the electronic service tool to check for active diagnostic Result: There are no active diagnostic codes.
2. ECM Flash File Flash file Result: The latest flash file is not installed.
A. Verify that the latest flash file is installed in the ECM. Install the latest flash file. Refer to Troubleshooting,
“Flash Programming” for the correct procedure. Verify
that the repair eliminates the fault.
Result: The latest flash file is installed.
3. Glow Plugs Glow plugs Result: The glow plugs are not operating correctly.
A. Check the operation of the glow plug circuit. Refer to Trouble- Make the necessary repairs. Verify that the repair cor-
shooting, “Glow Plug Starting Aid - Test”. rected the fault.
Result: The glow plugs are operating correctly.
4. Coolant Temperature Coolant Result: The water temperature regulator is not operat-
temperature ing correctly.
A. Check that the water temperature regulator is operating cor-
rectly. Refer to Systems Operation, Testing, and Adjusting, “Water Replace the water temperature regulator. Verify that the
Temperature Regulator - Test”. repair corrected the fault.
Result: The water temperature regulator is operating

correctly.
5. Cooling System Internal coolant Result: There is an internal coolant leak.

leak
A. Check for an internal coolant leak into the cylinder and/or the ex- Make the necessary repairs. Verify that the repair elimi-
haust. Refer to Systems Operation/Testing and Adjusting, “Cooling nated the fault.
System”.
Result: There is not an internal coolant leak.
(continued)
UENR4504 127
(Table 129, contd)

A. Check the fuel quality. Refer to Systems Operation, Testing, and Drain the fuel system and replace the fuel filters. Refer
Adjusting, “Fuel Quality - Test”. to the Operation and Maintenance Manual, “Fuel Sys-
tem Primary Filter (Water Separator) Element - Re-
B. Refer to Operation and Maintenance Manual for information on place” and Operation and Maintenance Manual, “Fuel
the proper characteristics of the fuel for the engine. System Filter - Replace”.
Fill the fuel system with fuel that meets the standard in
the Operation and Maintenance Manual, “Fluid
Recommendations”.
Prime the fuel system. Refer to the Operation and Main-

tenance Manual, “Fuel System - Prime”.
Verify that the procedure has eliminated the noise.
7. Valve Lash Valve lash Result: The valve lash is excessive.
Note: Excessive valve lash will cause a change in the timing of the The hydraulic lifter will compensate for all normal wear
opening and closing of the inlet and exhaust valves. Excessive of the components of the valve train.
valve lash can cause a reduction of the flow of combustion air into Repair or replace any excessively worn or damaged
the engine. Reduced flow of combustion air will increase the fuel components of the valve train.
consumption rate.
A. Check the valve lash. Refer to Systems Operation, Testing, and
Adjusting, “Engine Valve Lash - Inspect/Adjust”. Proceed to Test Step 8.
(continued)
128 UENR4504
(Table 129, contd)

8. Low Compression (Cylinder Pressure) Low compression Result: Low compression is recorded on one or more
cylinders.
ing, and Adjusting, “Compression - Test”. Possible causes of low compression are shown in the
following list:
·Loose glow plugs
·Faulty piston
·Worn valves

Attempt to start the engine. If the engine will not start,
contact the Dealer Solution Network (DSN).
9. Individual Malfunctioning Cylinders Cylinders Result: There is not a noticeable change in the sound
of the engine for at least one cylinder.
tool to perform the manual “Cylinder Cut Out Test” . As each cylin- Investigate the cause of the fault on any cylinder that is
der is cut out, listen for a change in the sound from the engine. not operating. Investigate the cause of the fault on any
When a cylinder is cut out, there should be a noticeable change in cylinder that is operating below normal performance.
Result: There is a noticeable change in the sound of
the engine for each cylinder.
i05874144
Exhaust System Contains Oil
Probable Causes
• Extended idle times
• Failed turbocharger seals

• Worn valve guide seals or faulty valve guide seals
• Worn valve guides

• Worn piston rings
steps are listed.
UENR4504 129
Table 130
1. Extended Idle Times Idle times Result The idle times are extensive.
A. Extended idle times will allow oil to pass into the exhaust Reduce the idle times.
system.
Result The idle times are not extensive.
2. Failed Turbocharger Seals Turbo seals Result: Oil is present in the inlet or exhaust manifold.
A. Check the inlet manifold and the exhaust manifold for oil. Replace the turbocharger. Verify the repair.
Result: Oil is not present in the inlet or exhaust manifold.
3. Worn Valve Guide Seals or Faulty Valve Guide Seals Valve guide Result: The valve guide seals are damaged.
seals
A. Inspect the valve guide seals for wear and for damage. Replace the valve guide seals. Verify the repair.
Result: The valve guide seals are not damaged.
4. Worn Valve Guides Valve guides Result: The valve guides are worn.
A. Inspect the valve guides for wear. Refer to the Specification If necessary, recondition the cylinder head. Verify the repair.
manual for the maximum permissible wear of the valve guides.
Result: The valve guides are not worn.
5. Worn Piston Rings Piston rings Result The piston rings are worn.
A. Remove the pistons. Refer to Disassembly and Assembly, “Pis- Replace the piston rings. Verify the repair.
tons and Connecting Rods - Remove”.
Result The piston rings are not worn.
B. Remove the piston rings from the pistons. Refer to Disassembly
and Assembly, “Pistons and Connecting Rods - Disassemble” Contact the Dealer Solution Network (DSN).
C. Inspect the pistons and piston rings for wear or damage. Refer
to the “Specifications” manual for further information.
130 UENR4504
i05874208
Fuel Consumption Is
Excessive
Probable Causes
• Misreading of fuel level

• Fuel leakage
• Fuel quality
• Quality of oil

• Coolant temperature
• Prolonged operation at idle speed
• Engine operating speed

• Cooling fan
• Reduced pressure of intake air
• Valve lash
Recommended Actions
Table 131
1. Diagnostic Codes Diagnostic Result: A diagnostic code is present.

codes
Note: Certain diagnostic codes and/or event codes indicate the Troubleshoot the diagnostic code and then verify that the
cause of high fuel consumption. fuel consumption is normal. Refer to Troubleshooting, “Diag-
nostic Trouble Codes”.
A. Use the electronic service tool to check for active or logged
codes. Result: A diagnostic code is not present.
2. Misreading of Fuel Level Fuel level Result: Fuel consumption is normal for the operating
conditions.
Note: Misreading of the fuel gauge can give a false indication of
fuel consumption. Return the unit to service.
A. Monitor the fuel consumption over a period of 50 engine Result: Fuel consumption is high for the operating
hours. conditions.
(continued)
UENR4504 131
(Table 131, contd)

3. Fuel Leakage Fuel leaks Result: Evidence of a fuel leak is found.
A. Check the engine for signs of fuel leakage. Repair or replace the component that is leaking fuel.
Result: No evidence of a fuel leak is found.
4. Fuel Quality Fuel quality Result: The fuel quality does not meet specifications.
Note: The grade of the fuel affects the rate of fuel consumption. Drain the fuel system and replace the fuel filters. Refer to
Refer to the engines Operation and Maintenance Manual for ad- the Operation and Maintenance Manual, “Fuel System Pri-
ditional information. mary Filter (Water Separator) Element - Replace” and Oper-
ation and Maintenance Manual, “Fuel System Filter -
Cold weather adversely affects the characteristics of the fuel. Replace”.
Refer to the Operation and Maintenance Manual for information
on improving the characteristics of the fuel during cold-weather Fill the fuel system with fuel that meets the standard in the
operation. Operation and Maintenance Manual, “Fluid
Recommendations”.
A. Check the fuel quality. Refer to Systems Operation, Testing, Prime the fuel system. Refer to the Operation and Mainte-
and Adjusting, “Fuel Quality - Test”. nance Manual, “Fuel System - Prime”.
B. Refer to Operation and Maintenance Manual for information Result: The fuel quality meets specifications.
on the proper characteristics of the fuel for the engine.
5. Quality of Oil Engine oil Result: The engine oil does not meet the required
quality specification.
Note: The nominal viscosity of the lubricating oil that is used in
the engine will affect the rate of fuel consumption. The viscosity Refill the oil system with oil of an acceptable quality. Refer to
of lubricating oil is defined by the SAE grade of the lubricating the applicable sections in the Operation and Maintenance
oil. The grade of the lubricating oil must be correct for the ambi- Manual.
ent conditions. Lubricating oil for high ambient temperatures will
affect fuel consumption in cold ambient temperatures. Result: The engine oil meets the required specification.
A. Check that the engine oil meets the required specification. Proceed to Test Step 6.
Refer to “Engine Oil” in the Operation and Maintenance Man-
ual, “Refill Capacities”.
6. Engine Accessories and Transmission Engine accesso- Result: The engine accessories and transmission are not
ries and OK.
A. Check that the engine accessories and transmission are oper- transmission
ating correctly. Make the necessary repairs.
B. Remove and inspect any engine accessories that may be Result: The engine accessories and transmission are OK.
adding unexpected load to the engine.
(continued)
132 UENR4504
(Table 131, contd)

7. Coolant Temperature Coolant Result: The water temperature regulator is not operating
temperature correctly.
Note: The operating temperature of the engine will affect the rate
of fuel consumption. Operation of the engine below the correct Replace the water temperature regulator. Verify that the re-
temperature will increase fuel consumption. Failure of the water pair corrected the fault.
temperature regulator can prevent the engine from operating at
the correct temperature. Result: The water temperature regulator is operating
correctly.
A. Check that the water temperature regulator is operating cor-
rectly. Refer to Systems Operation, Testing, and Adjusting, Proceed to Test Step 8.
“Water Temperature Regulator - Test”.
8. Prolonged Operation at Idle Speed Extended idle Result: The engine is operating at idle speed for extended
operation periods.
Note: Prolonged operation of the engine at idle speed increases
fuel consumption. When possible, stop the engine to conserve fuel.
A. Check for extended periods of engine operation at idle speed. Result: The engine is not operating at idle speed for ex-
tended periods.
9. Engine Operating Speed Engine speed Result: The engine has been operated at an unsuitable
speed.
The operating speed of the engine will affect the rate of fuel
consumption. Operate the engine at a suitable speed.
High engine speed will increase fuel consumption. At high en-
gine speeds, internal power losses in the engine increase and Result: The engine has been operated at a suitable speed.
more power is required to drive the alternator and the fan. These
losses of power increase fuel consumption. Proceed to Test Step 10.
Lugging down the engine to a low engine speed will increase
fuel consumption. At low engine speeds, the combustion effi-
ciency of the engine is reduced and more fuel is required.
A. Check that the engine has been operated at a suitable engine
speed.
10. Air Intake and Exhaust System Air and Exhaust Result: The air filter is restricted.
System
A. Check the air filter restriction indicator, if equipped. restrictions Replace the air filter.
B. Check the air intake and exhaust systems for the following Result: There are system restrictions.
defects:
Repair any defects in the air inlet and exhaust systems.
· Blockages
· Restrictions Result: The air intake and exhaust system is OK.
Refer to Systems Operation, Testing and Adjusting, “Air Inlet and Proceed to Test Step 11.
Exhaust System - Inspect”.
(continued)
UENR4504 133
(Table 131, contd)

11. Cooling Fan Cooling fan Result: The cooling fan is operating excessively.
Excessive operation of the cooling fan will increase fuel Repair or replace the faulty cooling fan components.
consumption.
Result: The cooling fan is not operating excessively.
A. Check the operation of the cooling fan.
12. Reduced Pressure of Intake Air Intake air Result: There is a leak in the intake air system.
Note: If the air pressure is lower than normal, the same power Repair the leak or replace the component that is causing the
can only be achieved by the following: leak.
· Higher engine speed Result: The turbocharger wastegate is not operating

· Injection of more fuel correctly.
Either of these conditions will increase the fuel consumption. Replace the turbocharger.
A. Check all pipes from the outlets of the turbocharger compres- Result: The air intake system and the wastegate are OK.
sor to the inlet manifold for leaks.
B. Check for the correct operation of the wastegate in the turbo-
charger. Refer to Systems Operation, Testing and Adjusting,
“Turbocharger - Inspect”.
13. Valve Lash Valve lash Result: The valve lash is excessive.
Note: Excessive valve lash will cause a change in the timing of The hydraulic lifter will compensate for all normal wear of
the opening and closing of the inlet and exhaust valves. Exces- the components of the valve train.
sive valve lash can cause a reduction of the flow of combustion Repair or replace any excessively worn or damaged compo-
air into the engine. Reduced flow of combustion air will increase nents of the valve train.
the fuel consumption rate.
A. Check the valve lash. Refer to Systems Operation, Testing,
and Adjusting, “Engine Valve Lash - Inspect”. Contact the Dealer Solution Network (DSN).
i05667092
Fuel Contains Water

Table 132
Diagnostic Trouble Codes for Fuel Contains Water

Code
97-15 Water In Fuel Indicator : The Electronic Control Module (ECM) detects the presence of water in the fuel for at least 60 seconds.
High - least severe (1)
If equipped, the warning lamp will come on.
The fault will be cleared when no fuel is detected for at least 0.6 seconds.
Note: Visual identification of water in the bowl may be Recommended Actions

impossible. Water may turn dark yellow in color in the
fuel system. The similarity in color would prevent the Note: Complete the procedure in the order in which
ability to differentiate the water from the fuel. the steps are listed.
134 UENR4504
Table 133
1. Drain the Fuel/Water Separator Bowl Fuel/water Result: The “Water-In-Fuel” warning disappears within 1
separator minute.
A. Turn the ignition key to the OFF position.
B. Drain the fuel/water separator bowl. Refer to the Operation and
Maintenance Manual, “Fuel System Primary Filter/Water Separator Result: The “Water-In-Fuel” warning remains on.
- Drain”.
C. If necessary, prime the fuel system. Refer to the Operation and
Maintenance Manual, “Fuel System - Prime”.
D. Turn the ignition key to the ON position. Do not start the engine.
Wait for 1 minute.
2. Confirm that there is no Water in the Fuel Water in fuel Result: The “Water-In-Fuel” warning does not reappear
within the 5 minutes.
Run the engine for 5 minutes.
Result: The “Water-In-Fuel” warning reappears within the 5

minutes.
The fuel supply is contaminated with water. Drain the fuel

tank and then fill the fuel tank with clean fuel.
Repeat the procedure from Test Step 1.
3. Water-In-Fuel Switch Water in fuel Result: The Water-In-Fuel switch required a repair.
switch
A. Check the operation of the Water-In-Fuel switch. Refer to Trou- Repeat the procedure from Test Step 1.
bleshooting, “Water In Fuel - Test”.
Result The Water-In-Fuel switch is OK.
The fuel supply is contaminated with water. Drain the fuel

tank and then fill the fuel tank with clean fuel.
Repeat the procedure from Test Step 1.
i05875495
Fuel Rail Pressure Problem

Table 134
Diagnostic Trouble Codes for the Fuel Rail Pressure

Code
157-0 Engine Injector Metering The Electronic Control Module (ECM) detects the following conditions:
Rail #1 Pressure : High -
most severe (3) The fuel rail pressure is greater than 199000 kPa (28863 psi) while the fuel rail Pressure Relief Valve
(PRV) has been activated.
If equipped, the warning lamp will flash. The engine will be derated.
(continued)
UENR4504 135
(Table 134, contd)


Code
157-2 Engine Injector Metering The ECM detects one of the following conditions:
Rail #1 Pressure : Erratic, The amount of fuel delivered by the high-pressure fuel pump is greater than 850 mL/min (29 oz/min) for
Intermittent, or Incorrect at least 2.5 seconds while the engine is at low idle.
157-16 Engine Injector Metering The ECM detects one of the following conditions:
Rail #1 Pressure : High -
moderate severity (2) The fuel rail pressure is greater than 195000 kPa (28283 psi) for at least 1 second.
OR
The measured fuel rail pressure is greater than the desired fuel rail pressure for at least 3.5 seconds.
OR
The fuel pressure remains too high after the keyswitch has been turned to the OFF position.
If the engine is running, the warning lamp will flash. The engine will be derated.
If the engine fuel pressure is high after the keyswitch has been turned to the OFF position, the warning
lamp will come on the next time that the keyswitch is turned to the ON position.
157-17 Engine Injector Metering The ECM detects the fuel rail pressure is less than 13000 kPa (1886 psi)(or 16000 kPa (2321 psi) de-
Rail #1 Pressure : Low - pending on engine operating conditions).
least severe (1) The fault has been detected for at least 0.6 seconds.
The diagnostic code will clear if the rail pressure is within normal operating range for at least 0.5
seconds.
The warning lamp will flash. Fuel injection will be disabled.
157-18 Engine Injector Metering The ECM detects that the measured fuel rail pressure is lower than the desired fuel rail pressure for at
Rail #1 Pressure : Low - least 5 seconds. The threshold for this diagnostic code is dependent on engine speed.
If equipped, the warning lamp will flash. The shutdown lamp will come on. The engine will be derated.
The engine may shut down.
1239-0 Engine Fuel Leakage 1 : The ECM detects that the amount of fuel being delivered by the high-pressure fuel pump is too high for
High - most severe (3) the engine operating conditions.
5571-2 High Pressure Common The ECM detects that the fuel rail pressure is out of the expected range after the fuel Pressure Relief
Rail Fuel Pressure Relief Valve (PRV) has been opened.
Valve : Erratic, Intermit- This can either be high pressure (relief valve not fully open) or low pressure (fuel leak).
tent, or Incorrect
5571-7 High Pressure Common The PRV has been activated.

Rail Fuel Pressure Relief
Valve : Not Responding The PRV activation is caused by another active diagnostic code. Troubleshoot any other active diagnos-
Properly tic codes. This diagnostic code will clear when the other fault has been rectified.
If equipped, the warning lamp will flash. The engine will shut down.
5571-10 High Pressure Common The ECM detects that the volume of fuel being delivered is too low to open the PRV during a PRV test.
Valve : Abnormal Rate of If equipped, the warning lamp will flash.
Change Troubleshoot any other diagnostic codes before attempting to test the PRV again.
(continued)
136 UENR4504
(Table 134, contd)


Code
5571-14 High Pressure Common The ECM detects one of the following conditions:
Rail Fuel Pressure Relief The PRV has been open for a total of at least 300 minutes.
Valve : Special Instruction OR
The PRV has been activated at least 50 times.
Perform this procedure to identify the cause of the PRV activation before replacing the PRV.
5571-16 High Pressure Common The ECM detects that the PRV is open.
Valve : High - moderate If equipped, the warning lamp will flash. The engine will be derated.
severity (2) This code will be reset when the PRV is closed and the keyswitch has been cycled.
Use this procedure in order to troubleshoot abnormal

fuel rail pressure.
Probable Causes
• Diagnostic trouble codes
• Fuel filters
• Fuel rail pressure sensor
• Fuel rail Pressure Relief Valve (PRV)

• High-pressure fuel pump
Recommended Actions

NOTICE
Contact with high pressure fuel may cause personal
injury or death. Wait 60 seconds after the engine has
stopped to allow fuel pressure to purge before any
service or repair is performed on the engine fuel lines.
UENR4504 137
Table 135
1. Diagnostic Codes Diagnostic codes Result: One of the diagnostic codes listed in Table 134
is active.
Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Proceed to Test Step 2.
B. Use the electronic service tool to check for active diagnostic Result: A diagnostic code that is not listed in Table 134
codes. is active.
Troubleshoot the code. Refer to Troubleshooting, “Diag-

nostic Trouble Codes”.
Return the engine to service.
2. Electrical Connectors Connectors Result: There are suspect connectors.
A. Check for the correct installation of the ECM J1/P1 and the J2/ Repair or replace connectors that are suspect.
P2 connectors. Check for correct installation of the connector on
the fuel rail pressure sensor. Result: There are no suspect connectors.
3. Fuel Filters Fuel filters Result: The filters have been replaced and the fault is
eliminated.
A. Replace the primary fuel filter and the secondary fuel filters. Re-
fer to the Operation and Maintenance Manual for further Return the unit to service.
information.
Result: The filters have been replaced and the fault is
still present.
(continued)
138 UENR4504
(Table 135, contd)

4. Fuel Rail Pressure Sensor Pressure sensor Result: The “Fuel Rail Pressure (absolute)” is more
than 5,000 kPa (725 psi).
A. Make sure that the engine has been shut down for at least 10
minutes. Use the electronic service tool to check the status of the Replace the fuel rail pressure sensor. Refer to Disas-
“Fuel Rail Pressure” sembly and Assembly, “Fuel Manifold (Rail) - Remove
and Install”.
When the fuel manifold has been replaced, use the elec-
tronic service tool to perform the “Rail Pressure Sensor
Replacement Reset” and the “Rail Pressure Valve
Learn Reset” .
Confirm that the fault has been eliminated.
Result: The “Fuel Rail Pressure (absolute)” is less than

5,000 kPa (725 psi).
(wax).
E. Check the pressures in the fuel system. Refer to Systems Oper-

ation, Testing, and Adjusting, “Fuel System Pressure - Test”
F. Check the diesel fuel for contamination. Refer to Systems Oper-

ation, Testing, and Adjusting, “Fuel Quality - Test”.


UENR4504 139
140 UENR4504
Table 136
6. Fuel Rail Pressure Relief Valve (PRV) Fuel in container Result: Fuel is present in the container.
A. Turn the keyswitch to the OFF position. Install a replacement fuel manifold. Refer to Disassem-
bly and Assembly, “Fuel Manifold (Rail) - Remove and
B. Disconnect plastic tube assembly (4) from fuel manifold (1). Re- Install”.
fer to Disassembly and Assembly, “Fuel Manifold (Rail) - Remove When the fuel manifold has been replaced, use the elec-
and Install”. tronic service tool to perform the “Rail Pressure Sensor
Replacement Reset” and the “Rail Pressure Valve
C. Securely seal the end of plastic tube assembly (4). Learn Reset” .
Note: Plastic tube assembly (4) must be sealed to prevent air in-
gress into the fuel system. Result: No fuel is present in the container.
D. Attach a length of hose to fuel manifold (1) and secure with a Proceed to Test Step 7.
clip at position (3).
E. Place the other end of the hose into a container that is suitable
for fuel. Ensure that the hose is secure and will not come out of the
container while the engine is running.
F. Turn the keyswitch to the ON position.
G. If the engine will start, use the electronic service tool to perform
the “High Rail Pressure Test” . This service test will run the engine
with an elevated fuel rail pressure for a limited time. At this pres-
sure, a PRV that is functioning correctly will remain closed. If the
engine will not start, crank the engine for a maximum of 30
seconds.
H. After the engine has stopped, check the container for fuel.

7. High-Pressure Fuel Pump Diagnostic codes
A. If all previous Test Steps have not identified a fault, and a fuel
rail pressure diagnostic code is still active, replace the high-pres- Result: A diagnostic code that is not listed in Table 134
sure fuel pump. is active.
Refer to Disassembly and Assembly, “Fuel Injection Pump - Re-
move” and refer to Disassembly and Assembly, “Fuel Injection Troubleshoot the code. Refer to Troubleshooting, “Diag-
Pump - Remove”. nostic Trouble Codes”.
B. Run the engine and use the electronic service tool to check for
active diagnostic codes. Result: One of the diagnostic codes listed in Table 134
is still active.

Fuel Temperature Is High Fuel Level in Tank
Probable causes If the level in the fuel tank is low, the hot fuel from the
high-pressure fuel system can raise the temperature
in the fuel tank. Replenish the fuel tank at the earliest
opportunity.
• Fuel level in tank
Location of the Fuel Tank
• Location of the fuel tank
Make sure that the fuel tank is not close to a heat
source. If necessary, shield the fuel tank from the
heat source.
UENR4504 141
i06017534
Inlet Air Is Restricted
The Electronic Control Module (ECM) detects a fault

with the air flow through the air filter. If the air flow has
been restricted, the ECM will generate one of the
following codes:
Table 137
Code for Inlet Air Restriction
J1939 Description Information
Code
The Electronic Control Module (ECM) detects the following
conditions:
The air filter restriction switch indicates that the air filter is
blocked.
107-15 Engine Air Filter 1 Differential Pressure : High - least severe (1)
The engine has been operating for at least 60 seconds.
The engine speed is at least 1800 rpm.
If equipped, the warning lamp will flash
The ECM detects that a 107-15 diagnostic code has been active
for at least 30 minutes.
Engine Air Filter 1 Differential Pressure: High - moderate severity
107-16
(2)
If equipped, the warning lamp will flash.
The engine will be derated.

steps are listed.
Table 138
1. Check the Air Filter Element Plugged Air Filter Result: The air filter is clogged.
A. Check the air intake system for plugged air filters or for damaged Repair: Clean or replace the air filter. Verify that the
air filters. If the engine is equipped with an air intake precleaner, problem is resolved.
verify the proper operation of the air intake precleaner.
Result: The air filter is not clogged.
2. Check the Air Inlet Piping Damaged Air Inlet Result: The air inlet piping is damaged or has
Piping restrictions.
A. Check the air inlet piping for damage or restrictions.
Repair: Repair the piping or replace the piping. Verify
that the problem is resolved.
Result: The air inlet piping does not have damage or

restrictions.
3. Check the Enclosure Ventilation Enclosure Ventilation Result: The engine does not have sufficient
ventilation.
A. Check that the engine has been installed in an enclosure that is
sufficiently ventilated. Repair: Repair the ventilation for the enclosure. Veri-
fy that the problem is resolved.
142 UENR4504
i05955248
Inlet Air Temperature Is High
Use this procedure to determine the cause of high air

inlet temperature.
Probable Causes
• High ambient air temperature
• Intake air restriction and/or high altitude

• Intake air from a heated area
Recommended Actions
Table 139

codes
tool and the Electronic Control Module (ECM). Refer to Trou-
bleshooting, “Electronic Service Tools”, if necessary. Result: There are no active or logged codes.
2. High Ambient Air Temperature Ambient Air Result: The ambient air temperature is not within the design
temperature specifications.
A. Determine if the ambient air temperature is within the de-
sign specifications for the cooling system and the air charge When possible, modify the cooling system and the air charge
cooler. cooler in order to make the system suitable for local
conditions.
Result: The ambient air temperature is within the design

specifications.
Operate the engine at a reduced load or operate the engine at

a reduced speed.
(continued)
UENR4504 143
(Table 139, contd)

3. Intake Air Restriction and/or High Altitude Intake air Result: There is a suspected intake air restriction.
problem
Check for blocked air filters. Check for obstructions in the air
A. Measure the intake manifold pressure while the engine is intake.
operating under load. For specific data, refer to the Technical
Marketing Information (TMI) for the engine. Replace the air filters or remove the obstruction from the air
intake.
Note: Low air pressure at the air intake for the turbochargers
can be caused by a restriction in the air intake or a high alti- Result: High altitude operation is suspected of causing the
tude. When the pressure of the intake air is low, the turbo- symptom.
chargers work harder in order to achieve the desired intake
manifold pressure. This increases intake air temperature. Make sure that the settings for the engine are correct for the
altitude.
Result: There are no air restrictions or altitude issues.
4. Intake Air from a Heated Area Intake air Result: The intake air is from a heated area.
temperature
A. Ensure that the air inlet system is not receiving air from a If necessary, relocate the air supply to the intake manifold to
heated area. the outside of the engine enclosure.
Check for air leaks in the pipe between the air inlet and the in-
let to the turbocharger compressor.
Result: The intake air is not from a heated area.
i05955263
Intake Manifold Air Pressure Is

High

Table 140
Diagnostic Trouble Codes for High Intake Manifold Air Pressure
1127-16 Engine Turbocharger 1 Boost Pressure : High - moderate The Electronic Control Module (ECM) detects that the ac-
severity (2) tual intake manifold air pressure is greater than the desired
intake manifold air pressure by 50 kPa (7.25 psi) for at
least 10 seconds.
If equipped, the warning lamp will flash. The engine will be

derated.
If the actual intake manifold pressure is within 25 kPa

(3.6 psi) of the desired intake manifold air pressure for at
least 11 minutes, the code will reset.
Probable Causes
• Air inlet and exhaust restrictions
• Turbocharger wastegate
• Wastegate regulator
144 UENR4504
Recommended Actions
Table 141
1. Air Inlet and Exhaust Restrictions Air inlet and ex- Result: Defects found in the air inlet or exhaust systems.
haust system
A. Check the air filter for damage. Repair any defects. Replace damaged components.
B. Check the air inlet and exhaust system for restrictions and/ Result: The air inlet and exhaust systems are OK.
or leaks. Refer to Systems Operation, Testing, and Adjusting,
“Air Inlet and Exhaust System - Inspect”. Proceed to Test Step 2.
2. Turbocharger Wastegate Turbocharger Result: There is a suspected fault in the wastegate or the
wastegate wastegate actuator.
A. Check the operation of the turbocharger wastegate.
Replace the turbocharger. Refer to Disassembly and Assem-
B. Check the operation of the wastegate actuator. Refer to bly, “Turbocharger - Remove” and Disassembly and Assembly,
Systems Operation, Testing, and Adjusting, “Turbocharger - “Turbocharger - Install”.
Inspect”.
Result: The wastegate and the wastegate actuator operate
correctly.
3. Wastegate Regulator Wastegate Result: Diagnostic codes are present that relate to the waste-
regulator gate regulator.
A. Use the electronic service tool to check for diagnostic trou-
ble codes that relate to the wastegate regulator. Rectify the cause of any related codes. Refer to Troubleshoot-
Result: There are no diagnostic codes that relate to the waste-

gate regulator.
i05955265
Intake Manifold Air Pressure Is

Low
UENR4504 145
Table 142
Diagnostic Trouble Codes for Low Intake Manifold Air Pressure
1127-18 Engine Turbocharger 1 Boost Pressure : Low The Electronic Control Module (ECM) detects the following conditions:
- moderate severity (2)
The actual intake manifold air pressure is less than the desired intake manifold
air pressure for at least 10 seconds. The difference between the two values is
dependent on engine operating conditions.
The engine speed is between 1000 rpm and 4000 rpm.
The engine coolant temperature is greater than 45° C (113° F).
There are no active 102 diagnostic codes for the intake manifold air pressure
sensor.
An active regeneration is not in progress.
There are no other active engine derates.
The fault will be cleared when the intake manifold air pressure is within the ac-
ceptable range for at least 11 minutes.
Probable Causes
• Intake air filter
• Air intake system

• Wastegate regulator
• Turbocharger
Recommended Actions
Table 143
1. Intake Air Filter Air filter Result: The air filter is blocked.
A. Check the air filter restriction indicator, if equipped. Replace the air filter element. Refer to the Operation and Main-
tenance Manual, “Engine Air Cleaner Element - Replace”.
B. Ensure that the air filter is clean and serviceable.
Result: The air filter is OK.
2. Air Intake System Air intake Result: The air intake system is blocked, restricted, damaged,
or loose.
A. Check the air intake system for the following defects:
Make all necessary repairs to the air intake system.
· Blockages
· Restrictions Result: The air intake system is OK.
· Damage to the air intake ducts and hoses
· Loose connections and air leaks Proceed to Test Step 3.
(continued)
146 UENR4504
(Table 143, contd)

3. Wastegate Regulator Wastegate Result: Diagnostic codes are present that relate to the waste-
regulator gate regulator.
A. Use the electronic service tool to check for diagnostic trou-
ble codes that relate to the wastegate regulator. Rectify the cause of any related codes. Refer to Troubleshoot-
Result: There are no diagnostic codes that relate to the waste-

gate regulator.
4. Turbocharger Turbocharger Result: There is a fault with the turbocharger.
Note: The turbocharger that is installed on the engine is a Replace the turbocharger. Refer to Disassembly and Assem-
nonserviceable item. If any mechanical fault exists, then the bly, “Turbocharger - Remove” and Disassembly and Assembly,
turbocharger must be replaced. “Turbocharger - Install”.
A. Check that the compressor housings for the turbochargers Result: The turbocharger is OK.
are free of dirt and debris.
B. Check that the turbine housings for the turbochargers are
free of dirt and debris.
C. Check that the turbine blades rotate freely in the

turbochargers.
i05955273
Intake Manifold Air

Temperature Is High
The Electronic Control Module (ECM) monitors the

intake manifold air for excessive temperature.
Use this procedure to determine the cause of high
intake manifold air temperature.
Probable Causes
• Coolant level
• Air-to-air aftercooler (ATAAC)

• Cooling fan
• Air inlet and exhaust system

• Ambient temperature
• Altitude
• Running condition
Recommended Actions
UENR4504 147
Table 144
1. Coolant Level Coolant Result: The coolant level is low.
A. Check that the coolant is filled to the correct level. Fill the coolant system to the correct level. Refer to the Opera-
tion and Maintenance Manual, “Coolant Level - Check”.
Note: If the coolant level is too low, air will get into the cooling
system. Air in the cooling system will cause a reduction in Result: The coolant level is OK.
coolant flow.
2. Air-to-Air Aftercooler (ATAAC) ATAAC Result: The ATAAC has excessive debris or is damaged.
A. Check the ATAAC for debris or damage. Clear the debris from the ATAAC or replace the ATAAC.
Note: Debris between the fins of the ATAAC core restricts air Result: The ATAAC is OK.
flow through the core.
3. Cooling Fan Cooling fan Result: The cooling fan is not operating correctly.
A. Check the operation of the cooling fan. Investigate the cause of the incorrect fan operation
Note: A fan that is not turning at the correct speed can result Result: The cooling fan is operating correctly.
in insufficient airflow through the aftercooler core.
4. Air Intake and Exhaust System Air intake and Result: The air intake or exhaust system is blocked, restricted,
exhaust damaged, or loose.
A. Check the air intake and exhaust system for the following
defects: Make all necessary repairs to the air intake system.
· Blockages Result: The air intake and exhaust system is OK.

· Restrictions
· Damage to the air intake ducts and hoses Proceed to Test Step 5.
· Loose connections and air leaks
5. Ambient Temperature Ambient Result: The ambient air temperature is high.

Temperature
A. Check for a high ambient temperature. Operate the engine at reduced speed or reduced power.
Note: When outside temperatures are too high, there is insuffi- Result: The ambient air temperature is OK.
cient temperature difference between the outside air and the
intake air. Proceed to Test Step 6.
(continued)
148 UENR4504
(Table 144, contd)

6. Altitude Altitude Result: The engine is being operated at high altitude.
A. Check for operation at high altitude. Operate the engine at reduced speed or reduced power.
Note: The cooling capacity of the ATAAC is reduced as the Result: The engine is not being operated at high altitude.
engine is operated at higher altitudes.
7. Running Condition Running Result: The engine is operating in the lug condition.
condition
A. Check that the engine is not operating in the lug condition. Reduce the load on the engine or, if possible, increase the
power rating of the engine.
Note: When the load that is applied to the engine is too large,
the engine will run in the lug condition. When the engine is Result: The engine is not operating in the lug condition.
running in the lug condition, engine rpm does not increase
with an increase of fuel. This lower engine rpm causes a re- Contact the Dealer Solution Network (DSN).
duction in coolant flow through the system.
UENR4504 149
i05955277
NOx Conversion Is Low

Table 145
Diagnostic Trouble Codes for NOx Conversion Is Low

Code
The ECM detects that the difference in NOx between the engine out NOx sensor and the
Aftertreatment #1 SCR Catalyst
tailpipe out NOx sensor is not within the expected range.
4364-17 Conversion Efficiency : Low - least
This value is measured when all other engine sensors are reading within a valid range and
severe (1)
the exhaust gas volume is in a steady state.
Table 146
Required Tools
Tool Part Number Part Description Qty
A T400236 Kit - Test 1

steps are listed.
150 UENR4504
Table 147
1. Check for Other Active Diagnostic Codes Diagnostic trou- Result: There is at least one other active diagnostic code
ble code
A. Establish communication between the electronic service tool Note: Troubleshoot all other active diagnostic codes be-
and the Electronic Control Module (ECM). Refer to Troubleshoot- fore continuing with this procedure.
Refer to Troubleshooting, “Diagnostic Trouble Codes” for
further information.
B. Check for active diagnostic codes
Result: A 4364-17 code is active or logged.
2. Check the DEF Quality DEF quality Result: The DEF quality is within the acceptable range.
standards
A. Use Tooling A to measure the Diesel Exhaust Fluid (DEF) Proceed to Test Step 3.
quality.
Result: The DEF quality is not within the acceptable
Refer to Systems Operation, Testing and Adjusting, “Diesel Ex- range.
haust Fluid Quality - Test” for the correct procedure.
Drain the DEF fluid from the tank. Refill the tank with DEF
that meets ISO 22241 quality standards.
3. Inspect All the DEF Lines for Leaks Leaks Result: The lines are leaking, damaged, pinched, or
disconnected.
B. Use the electronic service tool to perform the “DEF Dosing Sys-
tem Verification Test ” in order to pressurize the system. Refer to Result: The lines are not leaking, damaged, pinched, or
Troubleshooting, “Service Tool Features” for more information. disconnected.
C. Visually inspect all DEF lines from the DEF tank to the DEF in- Proceed to Test Step 4.
jector. Look for pinched, damaged, or disconnected lines.
D. Inspect the lines for leakage.
4. Check for Exhaust Leaks Exhaust leaks Result: Exhaust leaks are found.
A. Start the engine. Repair or replace the component that is causing an ex-
haust leak.
B. Check the exhaust system for leaks or damage.
C. Check all exhaust connections from the turbo outlet to the SCR Result: There were no exhaust leaks found.
outlet (tailpipe outlet).
D. Check for damage to the exhaust system insulation.
DEF dosing Result: The quantity collected is not within the acceptable
5. Perform the “ DEF Dosing System Accuracy Test”” range.
A. Perform the “DEF Dosing System Accuracy Test” . Refer to Sys- Replace the DEF injector. Refer to Disassembly and As-
tems Operation, Testing and Adjusting, “Aftertreatment SCR Sys- sembly, “DEF Injector and Mounting - Remove and
tem Dosing Test” for the correct procedure. Install”.
(continued)
UENR4504 151
(Table 147, contd)

Result: The quantity collected is within the desired range.
6. Check the DEF Pressure Line Restrictions, ob- Result: There are restrictions in the DEF pressure line.
structions, or
A. Turn the keyswitch to the OFF position for 2 minutes. leaks Proceed to Test Step 7.
B. Remove the DEF pressure line between the DEF pump and the Result: There are no restrictions or leaks in the lines.
DEF injector.
C. Check for ice, urea deposits, or debris in the DEF pressure line.
7. Check the Engine Breather System Breather System Result: Fault found in the engine breather system.
A. Ensure that the crankcase breather filter has been replaced ac- Make any necessary repairs.
cording to the maintenance interval schedule. Refer to Operation
and Maintenance Manual, “Engine Crankcase Breather Element - Result: The engine breather system is OK.
Replace”.
B. Check for correct operation of the crankcase pressure relief Contact the Dealer Solution Network (DSN).
valve. Refer to Troubleshooting, “Crankcase Breather Ejects Oil”.
i05948730
NRS Mass Flow Rate Problem
This procedure covers the following diagnostic

trouble code:
Table 148
Diagnostic Trouble Codes
J1939 Code Code Description Comments

2659-2 Engine Exhaust Gas Recirculation 1 Mass Flow Rate : Erratic, Intermittent, or The Electronic Control Module (ECM) will per-
Incorrect form a check on the Exhaust Gas Recircula-
tion (EGR) system when the engine is at
normal operating temperature and low idle.
This diagnostic code will become active when
the intake manifold pressure does not vary by
at least 1 kPa (0.14 psi) when the EGR valve
is operated over the full range.
Probable Causes
• Electrical connectors and harness
Recommended Actions
152 UENR4504
Table 149
1. Diagnostic Codes Diagnostic codes Result: A diagnostic code for the EGR valve is active or
logged.
A. Connect the electronic service tool to the diagnostic connec-
tor. If necessary, refer to Troubleshooting, “Electronic Service Rectify the EGR valve code. Refer to Troubleshooting, “Di-
Tools”. agnostic Trouble Codes”.
B. Turn the keyswitch to the ON position. Result: A 2659-2 diagnostic code is active.
C. Use the electronic service tool to check for active or logged Proceed to Test Step 2.
codes.
2. Inspect the Electrical Connectors and the Harness Connectors and Result: An electrical connector or a cable is not correctly
harness installed.
Install the connector or cable correctly.
B. Inspect the connectors for the components in the EGR sys-
tem. Refer to Troubleshooting, “Electrical Connector - Inspect”. Result: The harness is faulty.
C. Perform a 30 N (6.7 lb) pull test on each of the wires in any Install a replacement harness.
suspect connector and the connections at the ECM.
Result: The harness and connectors are OK.
D. Check that the ground connection on the ECM and the nega-
tive terminal on the battery are correctly installed. Proceed to Test Step 3.
E. Check the ground connection on the ECM for abrasions and

pinch points.
F. Check the harness for abrasion and pinch points from the
EGR components to the ECM.
H. Check that any suspect connector is installed correctly.
3. Check the Air Inlet and Exhaust System Air inlet and ex- Result: The air inlet system has a leak or is restricted.
haust system
A. Check the air inlet system for leaks and for restrictions. Clear any restrictions in the air inlet system.
B. Check the exhaust system for leaks and for restrictions. Repair any air leaks in the air inlet system.
Result: The exhaust system has a leak or is restricted.
Clear any restrictions in the exhaust system.
Repair any air leaks in the exhaust system.

work (DSN).
UENR4504 153
i05955289
Oil Consumption Is Excessive

Probable Causes
• Misreading oil level
• Oil leaks
• Engine crankcase breather
• Oil level
• Turbocharger
Recommended Actions
Table 150
1. Misreading Oil Level Oil level Result: The oil consumption is less than 0.1% of the fuel
consumption.
A. Accurately measure the consumption of oil and fuel over a
period of 50 engine hours. Oil consumption is within specification. Return the unit to
service
Result: The oil consumption is greater than 0.1% of the fuel

consumption.
2. Oil Leaks Oil leaks Result: An oil leak is identified.
A. Check for evidence of oil leaks on the engine. Rectify the cause of the oil leak.
B. Check for evidence of oil in the coolant. Result: Oil is present in the coolant.
Refer to Troubleshooting, “Coolant Contains Oil”.
No oil leaks are identified
(continued)
154 UENR4504
(Table 150, contd)

3. Engine Crankcase Breather Breather Result: The engine crankcase breather is blocked or
restricted.
A. Check the engine crankcase breather for blockage or
restrictions. Clear the blockage or restriction.
B. Check for excessive oil from the outlet of the breather. Result: Excessive oil is ejected from the outlet of the breather.
C. Check the centrifugal breather for a mechanical failure. Investigate the cause of the excessive oil content in the breath-
er flow. If necessary, replace the element in the breather. Refer
D. Check for oil around the crankcase breather pressure relief to Operation and Maintenance Manual, “Engine Crankcase
valve. Breather Element - Replace”.
Result: There is oil around the crankcase breather pressure

relief valve.
Refer to Troubleshooting, “Crankcase Breather Ejects Oil”.
Result: No oil is ejected through the breather.
4. Oil Level Oil level Result: The oil level in the engine is high.
A. Check for a high oil level in the engine. Make sure that the oil is not contaminated with fuel. Refer to
Troubleshooting, “Oil Contains Fuel”.
Make sure that the oil is not contaminated with coolant. Refer
to Troubleshooting, “Oil Contains Coolant”.
Remove the excess oil.
Result: The oil level is OK.
5. Air Intake and Exhaust System Air intake and Result: The air filter restriction indicator has operated or the
exhaust system air filter is blocked.
A. Check the air filter restriction indicator, if equipped.
Make sure that the air filter is clean and serviceable. If neces-
Check the air intake and the exhaust system for the following sary, replace the air filter.
defects:
Result: The air intake or the exhaust system is blocked, re-
· Blockages stricted, or damaged.
· Restrictions
· Damage to the air intake and exhaust lines and hose Repair the air intake or the exhaust system, as required.
Result: The air intake or the exhaust system is OK.
(continued)
UENR4504 155
(Table 150, contd)

6. Turbocharger Turbocharger Result: The oil drain for the turbocharger is blocked or
restricted.
Note: The turbocharger that is installed on this engine is a
nonserviceable item. If any mechanical fault exists, then the Remove the blockage or restriction. If necessary, replace the
turbocharger must be replaced. oil drain line.
A. Check that the oil drain for the turbocharger is not blocked Result: The turbocharger has an internal oil leak.
or restricted.
Replace the turbocharger.
B. Check the turbocharger for evidence of an internal oil leak.
Result: The turbocharger is OK.
7. Low Compression (Cylinder Pressure) Cylinder Result: The results of the compression test are outside the
compression specifications.
Testing, and Adjusting, “Compression - Test”. Investigate the cause and rectify any faults.
Note: Possible causes of low compression are shown in the

following list:
· Loose glow plugs

· Faulty piston
· Worn valves
i05955303
Oil Contains Coolant

Probable Causes

• Cylinder head
• Cylinder block
Recommended Actions
156 UENR4504
Table 151
1. Engine Oil Cooler Oil level Result: Evidence of coolant in the oil system is identified.
A. Drain the engine lubricating oil and coolant from the engine. Install a new oil cooler. Refer to Disassembly and Assembly,
Check for leaks in the oil cooler assembly. “Engine Oil Cooler - Remove” and Disassembly and Assembly,
Refer to Systems Operation, Testing, and Adjusting, “Cooling “Engine Oil Cooler - Install” for the correct procedure.
System” for the correct procedure.
Result: No evidence of coolant in the oil system is found.
2. Cylinder Head Gasket Cylinder head Result: The cylinder head gasket is faulty or shows signs of
gasket leakage.
A. Remove the cylinder head. Refer to Disassembly and As-
sembly, “Cylinder Head - Remove” for the correct procedure. Install a new cylinder head gasket.
Inspect the cylinder head gasket for faults and any signs of
leakage. Result: The cylinder head gasket is OK.
(continued)
UENR4504 157
(Table 151, contd)

3. Cylinder Head Cylinder head Result: The cylinder head is not within specification for
flatness.
A. Check the cylinder head for flatness. Refer to Systems Op-
eration, Testing, and Adjusting, “Cylinder Head - Inspect” for Install a new cylinder head. Refer to Disassembly and Assem-
the correct procedure. bly, “Cylinder Head - Install” for the correct procedure.
B. Check the mating face of the cylinder head for faults and Result: The cylinder head shows signs of a fault or leakage.
signs of leakage. If a fault is found, replace the cylinder head.
If signs of leakage are found, determine the cause of the leak- Install a new cylinder head. Refer to Disassembly and Assem-
age. Refer to Systems Operation, Testing, and Adjusting, “Cyl- bly, “Cylinder Head - Install” for the correct procedure.
inder Head - Inspect” for the correct procedure.
Result: An internal core plug in the cylinder head shows signs
C. Check the internal core plugs in the cylinder head for signs of leakage.
of leakage.
Replace the faulty core plug.
Result: The cylinder head is OK.
4. Cylinder Block Cylinder block Result: The top face of the cylinder block has a fault.
A. Inspect the top face of the cylinder block for faults and signs Replace the cylinder block.
of leakage.
Result: The top face of the cylinder block shows signs of
leakage.
Determine the cause of the leakage. Refer to Systems Opera-

tion, Testing, and Adjusting, “Cylinder Block - Inspect” for the
correct procedure.
Result: The cylinder block is OK.
Install the cylinder head. Refer to Disassembly and Assembly,

“Cylinder Head - Install”.
Remove the oil filter element. Install a new engine oil filter ele-
ment. Fill the engine with clean engine oil to the correct level.
Refer to the Operation and Maintenance Manual, “Engine Oil
and Filter - Change” for more information.
Fill the cooling system. Refer to the Operation and Mainte-

nance Manual for more information.
i05955310 A closed cup flash test can be performed in order to

detect fuel dilution. The flash test is designed to
Oil Contains Fuel measure the volatile parts of the fuel that are
remaining in the oil. Detecting less volatile fuel is
difficult. The less volatile fuel reduces the accuracy of
the flash test.
Measuring Fuel Dilution Since the flash test does not accurately detect
fuel dilution, do not use the flash test as the only
Diesel fuel is chemically similar to the lubricants that measure of fuel dilution. Instead, verify the dilution
are used in diesel engines. A slow fuel leak will blend by the following methods:
the fuel into the oil. Normal operating temperatures
may cause volatile parts of the fuel to vaporize. The • Gas chromatograph fuel dilution test
fuel that remains in the oil is less volatile.
• Oil viscosity
158 UENR4504
The test that uses a gas chromatograph is designed

to measure fuel dilution in crankcase oils. The gas
chromatograph can identify the small chemical
differences between diesel fuel and lubricating oil.
Even though the gas chromatograph provides a more
accurate measure of fuel dilution, always verify the
results with the viscosity test.
A significant level of fuel dilution reduces oil viscosity.
If an unacceptable level of fuel dilution is suspected,
the kinematic viscosity of the oil must be measured.
Fuel dilution that is greater than 10 percent will
usually cause viscosity that is less than the specified
viscosity grade. If the oil is still within the specified
viscosity grade, fuel dilution has not reached an
unacceptable level.
Verifying Fuel Dilution

Always verify fuel dilution by the combination of a
viscosity test and a gas chromatograph test. If the
result is in excess of 10 percent, investigate the
cause.
1. Obtain an oil test kit. Refer to table
Table 152
Oil Test Kits
Region Part Number
North America and South 29990014

America
Rest of the world 29990011
2. Follow the instructions that are supplied with the oil

test kit.
3. Obtain a sample of the oil from the engine. Refer to
Operation and Maintenance Manual, “Fluid
Recommendations - Engine Oil”.
4. Complete the form that is included with the oil test

kit.
5. Send the oil sample for analysis. Follow the
instructions that are included with the oil test kit.
Probable Causes
• Fuel injector seals
• Fuel injector tip
Recommended Actions
UENR4504 159
Table 153
1. Fuel Injector Seals Fuel injector Result: Injector seals are damaged.
seals
A. Check for signs of damage to the seals for the fuel Replace any damaged injector seals.
injectors. Change the engine oil and perform the “Engine Oil Life Reset”
. Refer to Operation and Maintenance Manual, “Engine Oil and
Filter - Change”.
Result: All injector seals are OK.
2. Fuel Injector Tip Fuel injector tip Result: A fuel injector is damaged.
A. Check for signs of damage to the fuel injectors. Check the Replace the fuel injector. Refer to Disassembly and Assembly,
fuel injector tip for cracks or breakage. “Electronic Unit Injector - Remove” and Disassembly and As-
sembly, “Electronic Unit Injector - Install”.
Change the engine oil and perform the “Engine Oil Life Reset”
. Refer to Operation and Maintenance Manual, “Engine Oil and
Filter - Change”.
Result: All fuel injectors are OK.
i05673615
Oil Pressure Is Low

Table 154
Diagnostic Trouble Codes for Low Engine Oil Pressure

Code
100-17 Engine Oil Pressure : Low The Electronic Control Module (ECM) detects that the engine oil pressure is low.
- least severe (1)
The engine speed is greater than 500 RPM.
If equipped, the warning lamp will come on and the oil pressure lamp will come on.
NOTICE
Do not operate the engine with low oil pressure.
Engine damage will result. If measured oil pressure is
low, discontinue engine operation until the fault is
corrected.
The Electronic Control Module (ECM) monitors the

engine oil pressure.
160 UENR4504
Probable Causes
• Visible Leaks
• Engine oil level
• Oil specification
• Engine oil filter

• Engine oil pressure switch
• Engine oil relief valve

• Fuel in the engine oil

• Piston cooling jets
• Engine oil suction tube

• Engine oil pump
• Bearing clearance
Recommended Actions
Table 155
1. Visible Leaks Visible leaks Result: There are visible oil leaks.
A. Thoroughly inspect the engine for oil leaks. Repair any leaks.
Result: There are no visible oil leaks
2. Engine Oil Level Oil level Result: The engine oil level is low.
A. Check the engine oil level. Fill the oil system to the full mark on the dipstick.
Result: The engine oil level is OK.
3. Oil Specification Oil specification Result: An incorrect specification of engine oil is being used.
A. Check that engine oil of the correct specification is being Drain the oil system and refill the oil system with engine oil of
used. Refer to the Operation and Maintenance Manual, “Refill the correct specification. Refer to Operation and Maintenance
Capacities and Recommendations”. Manual, “Engine Oil and Filter - Change”.
Result: The engine contains oil of the correct specification.
(continued)
UENR4504 161
(Table 155, contd)

4. Engine Oil Filter Oil filter Result: The oil filter is blocked.
A. Remove the engine oil filter. Refer to the Operation and Install a new oil filter. Refer to the Operation and Maintenance
Maintenance Manual, “Engine Oil and Filter - Change”. Manual, “Engine Oil and Filter - Change” for further
information.
B. Inspect the engine oil filter for evidence of blockage.
Result: The oil filter is OK.
Install a new oil filter. Refer to the Operation and Maintenance

Manual, “Engine Oil and Filter - Change” for further
information.
5. Engine Oil Pressure Switch Engine Oil Pres- Result: There is a fault with the oil pressure switch circuit.
sure Switch
A. Ensure that the engine oil pressure switch is operating cor- Make any necessary repairs. Refer to Troubleshooting,
rectly. Refer to Troubleshooting, “Switch Circuits - Test (En- “Switch Circuits - Test (Engine Oil Pressure Switch)”.
gine Oil Pressure Switch)”.
Result: The oil pressure switch circuit is OK.
6. Engine Oil Relief Valve Damage Result: The engine oil relief valve is damaged.
A. Inspect the engine oil relief valve for damage. Replace the oil relief valve. Refer to Disassembly and Assem-
bly, “Engine Oil Relief Valve - Remove and Install”.
Result: The engine oil relief valve is OK.
7. Engine Oil Cooler Oil cooler Result: The oil cooler has signs of damage or restriction.
A. Check the oil cooler for signs of damage or restrictions. Install a new oil cooler. Refer to Disassembly and Assembly,
“Engine Oil Cooler - Remove” and Disassembly and Assembly,
“Engine Oil Cooler - Install”.
Result: The oil cooler is OK.
8. Fuel in the Engine Oil Oil Result: The oil contains fuel.
contamination
A. Check fuel contamination of the engine oil. Refer to Trou- Refer to Troubleshooting, “Oil Contains Fuel”.
bleshooting, “Oil Contains Fuel”.
Result: The oil is not contaminated.
(continued)
162 UENR4504
(Table 155, contd)

9. Piston Cooling Jets Piston cooling Result: A piston cooling jet is cracked, damaged, or missing.
jets
A. Inspect the piston cooling jets for cracks, damage, or miss- Install a new piston cooling jet. Refer to Disassembly and As-
ing jets. sembly, “Piston Cooling Jets - Remove and Install”.
Result: The piston cooling jets are OK.
10. Engine Oil Suction Tube Oil suction tube Result: The inlet screen on the oil suction tube is blocked with
debris.
A. Check the inlet screen on the oil suction tube and remove
any material that may be restricting oil flow. Remove the debris from the inlet screen.
B. Check the joints of the oil suction tube for cracks or a dam- Result: The oil suction tube is cracked.
aged joint.
Install a new oil suction tube.
Note: Cracks or damage may allow air leakage into the supply
to the oil pump. The oil suction tube is OK.
11. Engine Oil Pump Oil pump Result: A component in the oil pump is not within
specification.
A. Inspect the components of the engine oil pump for exces-
sive wear. Repair the oil pump or replace the oil pump, if necessary. Refer
to Disassembly and Assembly, “Engine Oil Pump - Remove”
and Disassembly and Assembly, “Engine Oil Pump - Install”.
The oil pump is OK.
12. Bearing Clearance Bearing Result: An engine bearing is not within specification.
clearance
A. Inspect the engine components for excessive bearing clear- Install a new bearing. Refer to Disassembly and Assembly.
ance or damaged bearings. Inspect the following components
for excessive bearing clearance: Result: All engine bearings are within specification.
· Crankshaft main bearings If the fault is still present there may be an open circuit condition
· Connecting rod bearings in the oil pressure switch circuit. Refer to Troubleshooting,
· Camshaft front bearing “Switch Circuits - Test (Engine Oil Pressure Switch)”.
· Idler gear bearing
i05955328 Probable Causes

Power Is Intermittently Low or • Diagnostic codes
Power Cutout Is Intermittent • Electrical connectors
• ECM connection
Note: Use this procedure only if the engine does not • Fuel system inspection
shut down completely.
UENR4504 163
Recommended Actions
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

Table 156

codes
tool and the Electronic Control Module (ECM). Refer to Trou- Refer to Troubleshooting, “Diagnostic Trouble Codes”.
bleshooting, “Electronic Service Tools”, if necessary.
Result: There are no active or logged codes.
B. Use the electronic service tool to check for active diagnostic
2. Electrical Connectors Electrical Result: An electrical connector is damaged.

connectors
A. Check all electrical connectors for damage. Refer to Trou- Repair the electrical connector or replace the electrical
bleshooting, “Electrical Connectors - Inspect”. connector.
B. Make sure that all the connector seals are in place and that Result: A connector seal is displaced or missing or an electri-
the connectors have been correctly installed. cal connector is not correctly installed.
Repair the electrical connector or replace the electrical

connector.
Result: All electrical connectors are OK.
3. ECM Connection ECM connection Result: An ECM connector is not correctly installed.
Repair the electrical connector or replace the electrical

A. Check that the P2/J2 and P1/J1 connectors are correctly connector.
installed.
Result: Both ECM connectors are correctly installed.
Note: If a fault is suspected with the ECM power or ground
connections, refer to Troubleshooting, “Electrical Power Sup- Proceed to Test Step 4.
ply - Test”.
(continued)
164 UENR4504
(Table 156, contd)

fuel (wax).
D. Check that the low-pressure fuel lines are correctly

installed.

Test”


tems Operation, Testing, and Adjusting, “Fuel System -
Prime”.
5. Fuel Filters Fault cleared Result: The fault has been rectified.
Refer to the Operation and Maintenance Manual, “Fuel Sys-
tem Primary Filter (Water Separator) Element - Replace”. Result: The fault is still present.
B. Run the engine in the conditions that the fault occurred. Proceed to Test Step 6.
6. Air Inlet and Exhaust System Defects Result: A defect was found in the air intake or exhaust
system.
B. Ensure that the air filter is clean and serviceable
Result: No defects found in the air intake or exhaust systems.
C. Check the air intake and exhaust systems for the following
defects: Contact the Dealer Solution Network (DSN).
· Blockages
· Restrictions
UENR4504 165
i05918565
SCR Catalyst Has Incorrect Inlet Temperature

Table 157
Diagnostic Trouble Code for SCR Catalyst Has Incorrect Inlet Temperature
J1939 Code Description Comments

Code
Aftertreatment 1 Diesel Exhaust Fluid Dosing Tem- The Electronic Control Module (ECM) detects that the difference between
4337-10 perature : Abnormal Rate of Change the Selective Catalytic Reduction (SCR) catalyst intake temperature and
the ambient air temperature is implausible.

steps are listed.
Table 158
1. Check for Diagnostic Trouble Codes Diagnostic trou- Result: A 4337-10 diagnostic code is active or recently
ble codes logged.
A. Turn the keyswitch to the ON position. Do not start the engine. Proceed to Test Step 2.
B. Connect to the electronic service tool. Result: An associated code other than 4337-10 is active
or recently logged.
C. Check for active or recently logged diagnostic trouble codes. Troubleshoot the logged or active code. Refer to Trouble-
shooting, “Diagnostic Trouble Codes”.
2. Check the Exhaust System Exhaust System Result: The exhaust system has a gas leak.
A. Check the exhaust system for gas leaks between the turbo- Make the necessary repairs.
charger the exhaust tail pipe.
Use the electronic service tool to clear all logged diagnos-
B. Check for gas leaks around all of the sensors in the aftertreat- tic codes and verify that the repair eliminates the fault.
ment system.
Result: The exhaust system insulation is damaged or
C. Check for missing or damaged exhaust system insulation. missing.
Use the electronic service tool to clear all logged diagnos-

tic codes and verify that the repair eliminates the fault.
Result: The exhaust system is OK.
3. Install a Replacement SCR Inlet Temperature Sensor Diagnostic code Result: The 4337-10 diagnostic code is no longer active.
A. Turn the keyswitch to the OFF position. Return the unit to service.
B. Install a replacement SCR inlet temperature sensor. Refer to Result: The 4337-10 diagnostic code is still active.
Disassembly and Assembly.
C. Start the engine.
D. Use the electronic service tool to check for an active 4337-10 di-
agnostic code.
166 UENR4504
i05901698
SCR Warning System Problem
Operator Level Inducement

Inducements are engine derates or other actions
intended to prompt the operator to repair or maintain
the emission control system.
Inducement strategies are control actions required by
EPA/ARB Tier 4 and EU Stage IV regulations. An
inducement strategy ensures prompt correction of
various failures in the engine NOx emission control
system. The strategy requires actions to limit engine
performance and defines required the following
indications while the control actions are imposed:
• Lamps
• Messages
• Audible alarms
Table 159
Diagnostic Trouble Codes for SCR Warning System Problem
This code is a Level 1 inducement associated with an emission acti-

Aftertreatment Selective Catalytic Reduction Opera-
5245-15 vated fault.
tor Inducement Active : High - most severe (3)
The Emissions System Malfunction Lamp is on.

vated fault.
Aftertreatment Selective Catalytic Reduction Opera-
5245-16 The Emissions System Malfunction Lamp is on and the Action Lamp
tor Inducement Active : High - moderate severity (2)
is flashing.
The engine is derated.

vated fault.
Aftertreatment Selective Catalytic Reduction Opera- The Emissions System Malfunction lamp is on, the Action lamp is
5245-0
tor Inducement Active : High - most severe (3) flashing, and the warning horn may sound.

Aftertreatment SCR Operator Inducement Severity :
High - least severe (1)

vated fault.
Aftertreatment SCR Operator Inducement Severity :
High - moderate severity (2)
is flashing.

vated fault.
Aftertreatment SCR Operator Inducement Severity : The Emissions System Malfunction lamp is on, the Action lamp is
5246-0
High - most severe (3) flashing, and the stop lamp is on.
(continued)
UENR4504 167
(Table 159, contd)

Diagnostic Trouble Codes for SCR Warning System Problem
Emission Control System Operator Inducement Se-
verity : High - least severe (1)

vated fault.
Emission Control System Operator Inducement Se-
verity : High - moderate severity (2)
is flashing.
Associated Codes
Troubleshoot any associated diagnostic codes listed
in Table 160 that are present. Refer to “Inducement
Type” in Table 160 for the correct Inducement table.
Table 160
Associated Codes
J1939 Code Code Description Inducement Type
27-3 EGR #1 Valve Position : Voltage Above Normal EGR Inducement
27-4 EGR #1 Valve Position : Voltage Below Normal EGR Inducement
Engine Intake Manifold #1 Pressure : Voltage Above SCR/Electrical System Inducement

102-3
Normal
Engine Intake Manifold #1 Pressure : Voltage Below SCR/Electrical System Inducement
102-4
Normal
Engine Intake Manifold #1 Pressure : Data Drifted EGR Inducement
102-20
High
Engine Intake Manifold #1 Pressure : Data Drifted EGR Inducement

102-21
Low
Engine Intake Manifold #1 Temperature : Voltage SCR/Electrical System Inducement
105-3
Above Normal
Engine Intake Manifold #1 Temperature : Voltage Be- SCR/Electrical System Inducement
105-4
low Normal
Engine Injector Metering Rail #1 Pressure : High - EGR Inducement
157-0
most severe (3)
Engine Injector Metering Rail #1 Pressure : Erratic, EGR Inducement

157-2
Intermittent, or Incorrect
Engine Injector Metering Rail #1 Pressure : High - EGR Inducement

157-16
Engine Injector Metering Rail #1 Pressure : Low - EGR Inducement

157-18
Battery Potential / Power Input #1 : Voltage Above SCR/Electrical System Inducement

168-3
Normal
Battery Potential / Power Input #1 : Voltage Below SCR/Electrical System Inducement
168-4
Normal
Engine Exhaust Gas Temperature : Voltage Above EGR Inducement
173-3
Normal
Engine Exhaust Gas Temperature : Voltage Below EGR Inducement
173-4
Normal
Engine Fuel Injection Pump Fuel Control Valve : Cur- EGR Inducement
1076-5
rent Below Normal
(continued)
168 UENR4504
(Table 160, contd)

Engine Fuel Injection Pump Fuel Control Valve : Cur- EGR Inducement
1076-6
rent Above Normal
Engine Turbocharger 1 Boost Pressure : High - mod- EGR Inducement
1127-16
erate severity (2)
Engine Turbocharger 1 Boost Pressure : Low - mod- EGR Inducement

1127-18
erate severity (2)
Engine Turbocharger 1 Wastegate Drive : Current EGR Inducement

1188-5
Below Normal
Engine Exhaust Gas Pressure : Voltage Above EGR Inducement
1209-3
Normal
Engine Exhaust Gas Pressure : Voltage Below EGR Inducement
1209-4
Normal
1231-9 J1939 Network #2 : Abnormal Update Rate SCR/Electrical System Inducement
1239-0 Engine Fuel Leakage 1 : High - most severe (3) EGR Inducement
1761-19 Aftertreatment #1 DEF Tank Level : Data Error SCR/Electrical System Inducement
Engine Exhaust Gas Recirculation 1 Mass Flow Rate EGR Inducement

2659-2
: Erratic, Intermittent, or Incorrect
Engine Exhaust Gas Recirculation (EGR) Valve Con- EGR Inducement

2791-5
trol : Current Below Normal
Engine Exhaust Gas Recirculation (EGR) Valve Con- EGR Inducement
2791-6
trol : Current Above Normal
2840-12 ECU Instance : Failure SCR/Electrical System Inducement
3031-12 Aftertreatment #1 DEF Tank Temperature : Failure SCR/Electrical System Inducement
Aftertreatment #1 DEF Tank Temperature : High - SCR/Electrical System Inducement

3031-16
Aftertreatment #1 Intake NOx : Erratic, Intermittent, SCR/Electrical System Inducement

3216-2
or Incorrect
Aftertreatment #1 Intake NOx : Current Below SCR/Electrical System Inducement
3216-5
Normal
Aftertreatment #1 Intake NOx : Current Above SCR/Electrical System Inducement
3216-6
Normal
Aftertreatment #1 Intake NOx : Abnormal Rate of SCR/Electrical System Inducement
3216-10
Change
3216-19 Aftertreatment #1 Intake NOx : Data Error SCR/Electrical System Inducement
Aftertreatment #1 Outlet NOx : Erratic, Intermittent, SCR/Electrical System Inducement

3226-2
or Incorrect
Aftertreatment #1 Outlet NOx : Current Below SCR/Electrical System Inducement
3226-5
Normal
Aftertreatment #1 Outlet NOx : Current Above SCR/Electrical System Inducement
3226-6
Normal
Aftertreatment #1 Outlet NOx : Abnormal Rate of SCR/Electrical System Inducement
3226-10
Change
3226-19 Aftertreatment #1 Outlet NOx : Data Error SCR/Electrical System Inducement
Aftertreatment #1 DEF Dosing Unit Input Lines : Not SCR/Electrical System Inducement
3362-7
Responding Properly
Aftertreatment #1 DEF Tank Heater : Current Below SCR/Electrical System Inducement

3363-5
Normal
(continued)
UENR4504 169
(Table 160, contd)

Aftertreatment #1 DEF Tank Heater : Current Above SCR/Electrical System Inducement
3363-6
Normal
Sensor Supply Voltage 1 : Erratic, Intermittent, or SCR/Electrical System Inducement
3509-2
Incorrect
Aftertreatment #1 DEF Concentration : Erratic, Inter- DEF Quality Inducement
3516-2
mittent, or Incorrect
Aftertreatment #1 DEF Concentration : Special DEF Quality Inducement

3516-14
Instruction
3521-19 Aftertreatment #1 DEF Property : Data Error SCR/Electrical System Inducement
Aftertreatment #1 SCR System State : Not Respond- SCR/Electrical System Inducement

4332-7
ing Properly
Aftertreatment 1 Diesel Exhaust Fluid Doser Abso- SCR/Electrical System Inducement

4334-0
lute Pressure : High - most severe (3)

4334-7
lute Pressure : Not Responding Properly

4334-10
lute Pressure : Abnormal Rate of Change

4334-16
lute Pressure : High - moderate severity (2)

4334-18
lute Pressure : Low - moderate severity (2)
Aftertreatment #1 DEF Line Heater #1 : Current Be- SCR/Electrical System Inducement

4354-5
low Normal
Aftertreatment #1 DEF Line Heater #1 : Current SCR/Electrical System Inducement
4354-6
Above Normal
Aftertreatment #1 DEF Line Heater #2 : Current Be- SCR/Electrical System Inducement
4355-5
low Normal
Aftertreatment #1 DEF Line Heater #2 : Current SCR/Electrical System Inducement
4355-6
Above Normal
Aftertreatment #1 SCR Catalyst Intake Gas Temper- SCR/Electrical System Inducement
4360-3
ature : Voltage Above Normal
Aftertreatment #1 SCR Catalyst Intake Gas Temper- SCR/Electrical System Inducement

4360-4
ature : Voltage Below Normal
Aftertreatment #1 SCR Catalyst Outlet Gas Temper- SCR/Electrical System Inducement

4363-3
Aftertreatment #1 SCR Catalyst Outlet Gas Temper- SCR/Electrical System Inducement

4363-4
Aftertreatment #1 SCR Catalyst Conversion Effi- SCR/Electrical System Inducement

4364-17
ciency : Low - least severe (1)
Aftertreatment 1 Outlet NH3 : Erratic, Intermittent, or SCR/Electrical System Inducement

4377-2
Incorrect
4377-4 Aftertreatment 1 Outlet NH3 : Voltage Below Normal SCR/Electrical System Inducement
Aftertreatment 1 Outlet NH3 : Not Responding SCR/Electrical System Inducement

4377-7
Properly
4377-19 Aftertreatment 1 Outlet NH3 : Data Error SCR/Electrical System Inducement
Aftertreatment 1 Outlet NH3 Gas Sensor Heater SCR/Electrical System Inducement

4383-5
Control : Current Below Normal
(continued)
170 UENR4504
(Table 160, contd)

Aftertreatment 1 Outlet NH3 Gas Sensor Heater SCR/Electrical System Inducement
4383-6
Control : Current Above Normal
Aftertreatment 1 Intake NOx Sensor Heater Ratio : SCR/Electrical System Inducement
5024-5
Current Below Normal
Aftertreatment 1 Intake NOx Sensor Heater Ratio : SCR/Electrical System Inducement
5024-6
Current Above Normal
Aftertreatment 1 Outlet NOx Sensor Heater Ratio : SCR/Electrical System Inducement
5031-5
Aftertreatment 1 Outlet NOx Sensor Heater Ratio : SCR/Electrical System Inducement
5031-6
Aftertreatment Diesel Exhaust Fluid Dosing Valve : SCR/Electrical System Inducement
5394-3
Voltage Above Normal

5394-4
Voltage Below Normal

5394-5
5394-6
Engine Throttle Actuator #1 : Not Responding EGR Inducement
5419-7
Properly
Aftertreatment #1 DEF Pump State : Current Below SCR/Electrical System Inducement

5435-5
Normal
Aftertreatment #1 DEF Pump State : Current Above SCR/Electrical System Inducement
5435-6
Normal
High Pressure Common Rail Fuel Pressure Relief EGR Inducement
5571-7
Valve : Not Responding Properly
High Pressure Common Rail Fuel Pressure Relief EGR Inducement

5571-16
Valve : High - moderate severity (2)
Aftertreatment #1 Diesel Exhaust Fluid Pump Heater SCR/Electrical System Inducement

5706-5
: Current Below Normal
Table 161
1. Check for Associated Codes Associated Result: There are associated diagnostic codes.
Codes
A. Connect the electronic service tool to the diagnostic connector. Troubleshoot the associated codes. Refer to Trouble-
shooting, “Diagnostic Trouble Codes” for the proper
B. Turn the keyswitch to the ON position. procedure.
C. Use the electronic service tool to check for active diagnostic

codes.
Inducement for low-level DEF

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.
UENR4504 171
Table 162
DEF in Tank Level
Warning Stop Indicator DEF Low Lev- Emission Mal- DEF in Tank Engine Power Time Comment Action
Indicator el Indicator function Level
Indicator
OFF OFF OFF OFF - Full Power - Normal None
Operation
OFF OFF On Solid OFF Less than 20 Full Power - Low DEF Indi- Stop Engine
Percent cator Active and Fill DEF
Tank
ON Solid OFF ON Solid ON Solid Less than Ten Full Power - Level 1 Indica-
Percent tors Active
ON Flashing OFF On Solid ON Flashing Less than Five Engine will Derate Timer A Level 2 In-
Slowly Slowly Percent Start to be Starts. ducement is
Derated Active
ON Flashing ON Solid ON Flashing ON Flashing Empty Tank Derate to en- Start of 30 Mi- A Level 3 in-
Fast Fast Fast gine Power nute Timer ducement is
Active
ON Flashing ON Solid ON Flashing ON Flashing Engine will A Level 3 In-
Fast Fast Fast Only Operate ducement is
at Low Idle. Active
172 UENR4504
Inducement for Poor DEF Quality

Table 163
Inducement for Poor DEF Quality
Warning Stop Indicator DEF Quality Emission Mal- Engine Power Time Comment Action
Indicator Indicator function
Indicator
OFF OFF OFF OFF Full Power - Normal None
Operation
On Solid OFF On Solid On Solid Full Power Start of 50 Mi- DEF Quality Out Stop Engine
nute Timer of Range Level and Check DEF
1 Inducement is Quality.
Active Refer to Sys-
tems Operation
ON Flashing OFF ON Solid ON Flashing Start of Engine Start of 40 Mi- A Level 2 In-
Testing and Ad-
Slowly Slowly Derate nute Derate ducement is
justing, “Diesel
Ramp Active
Exhaust fluid
ON Flashing ON Solid ON Solid ON Flashing Full Engine At 210 Minutes A Level 3 In- Quality - Test”
Fast Fast Derate. ducement is for More
Active Information.
Low Idle (RPM)
Only
UENR4504 173
SCR/Electrical System Inducements

Table 164
SCR System Inducements
Warning Indicator Stop Indicator Emission Malfunc- Engine Power Time Comment Action
tion Indicator
OFF OFF OFF Full Power - Normal Operation None
ON Solid or Slow OFF ON Solid Start of Engine Timer Starts, 240 A Level 1 Induce- Troubleshoot any as-
Flashing (1) Power Derate Minutes Before Full ment is Active sociated diagnostic
Derate codes. Refer to
ON Flashing OFF ON Flashing Derate to Engine A Level 2 Induce- Troubleshooting, “Di-
Slowly Slowly Power and Speed ment is Active agnostic Trouble
Codes”.
ON Flashing Fast ON Solid ON Flashing Fast Full Engine Derate A Level 3 Induce-
ment is Active
Low Idle (RPM)
Only
(1) Lamp mode will depend on the issue that has been identified.
174 UENR4504
EGR System Inducements

Table 165
EGR System Inducements
Warning Indicator Stop Indicator Emission Malfunc- Engine Power Time Comment Action
tion Indicator
OFF OFF OFF Full Power - Normal Operation None
ON Solid or Slow OFF ON Solid Start of Engine Timer Starts, 210 A Level 1 Induce- Troubleshoot any as-
Flashing (1) Derate Minutes Before Full ment is Active sociated diagnostic
Derate codes. Refer to Trou-
ON Flashing OFF ON Flashing Derate to Engine A Level 2 Induce- bleshooting, “Diag-
Slowly Slowly Power and Speed ment is Active nostic Trouble
Codes”.
(1) Lamp mode will depend on the issue that has been identified.
i05956248
Valve Lash Is Excessive

Probable Causes
• Lubrication
Recommended Actions
Table 166
1. Lubrication Lubrication Result: The oil flow to the valve mechanism is insufficient.
A. Remove the valve mechanism cover. Refer to Disassembly Make sure that the passages for the engine oil are clear.
and Assembly, “Valve Mechanism Cover - Remove and In-
stall” for the correct procedure. Result: The oil flow to the valve mechanism is OK.
B. Crank the engine and check the lubrication in the valve Proceed to Test Step 2.
compartment. Ensure that there is adequate engine oil flow in
the valve compartment. The passages for the engine oil must
be clean.
Note: Do not run the engine with the valve mechanism cover
removed.
2. Valve Train Components Valve train Result: A valve train component is worn, bent, or not clean.
components
A. Inspect the following components of the valve train for ab- Repair or replace the component. Refer to Disassembly and
normal or excessive wear, straightness, and cleanliness: Assembly.
· Rocker arms Note: If the camshaft is replaced, new valve lifters must also
· Pushrods be installed.
· Hydraulic lifters
· Camshaft Result: All the valve train components are OK.
· Valve stems
· Rocker shafts Contact the Dealer Solution Network (DSN).
UENR4504 175
Troubleshooting with a Diagnostic Code
Troubleshooting with a
Diagnostic Code
i05883110
The following table lists all the J1939 diagnostic

trouble codes for the engine. The table includes a
description for each code and the recommended
troubleshooting procedure that must be performed.
Table 167
J1939 Code Description Refer to Procedure

27-3 EGR #1 Valve Position : Voltage Above Normal Valve Position - Test
27-4 EGR #1 Valve Position : Voltage Below Normal Valve Position - Test
29-3 Accelerator Pedal Position #2 : Voltage Above Normal Speed Control (Analog) - Test
29-4 Accelerator Pedal Position #2 : Voltage Below Normal Speed Control (Analog) - Test
51-3 Engine Throttle Position : Voltage Above Normal Valve Position - Test
51-4 Engine Throttle Position : Voltage Below Normal Valve Position - Test
91-3 Accelerator Pedal Position #1 : Voltage Above Normal Speed Control (Analog) - Test
91-4 Accelerator Pedal Position #1 : Voltage Below Normal Speed Control (Analog) - Test
97-15 Water In Fuel Indicator : High - least severe (1) Fuel Contains Water
100-2 Engine Oil Pressure : Erratic, Intermittent, or Incorrect Switch Circuits - Test (Oil Pressure Switch)
100-17 Engine Oil Pressure : Low - least severe (1) Oil Pressure Is Low
102-3 Engine Intake Manifold #1 Pressure : Voltage Above Normal Sensor Signal (Analog, Active) - Test
102-4 Engine Intake Manifold #1 Pressure : Voltage Below Normal Sensor Signal (Analog, Active) - Test
102-20 Engine Intake Manifold #1 Pressure : Data Drifted High Sensor Signal (Analog, Active) - Test
102-21 Engine Intake Manifold #1 Pressure : Data Drifted Low Sensor Signal (Analog, Active) - Test
105-3 Engine Intake Manifold #1 Temperature : Voltage Above Normal Sensor Signal (Analog, Passive) - Test
105-4 Engine Intake Manifold #1 Temperature : Voltage Below Normal Sensor Signal (Analog, Passive) - Test
Engine Air Filter 1 Differential Pressure : Erratic, Intermittent, or

107-2 Switch Circuits - Test (Air Filter Restriction Switch)
Incorrect
107-15 Engine Air Filter 1 Differential Pressure : High - least severe (1) Inlet Air Is Restricted
Engine Air Filter 1 Differential Pressure : High - moderate se-

107-16 Inlet Air Is Restricted
verity (2)
108-3 Barometric Pressure : Voltage Above Normal Sensor Signal (Analog, Active) - Test
108-4 Barometric Pressure : Voltage Below Normal Sensor Signal (Analog, Active) - Test
110-3 Engine Coolant Temperature : Voltage Above Normal Sensor Signal (Analog, Passive) - Test
110-4 Engine Coolant Temperature : Voltage Below Normal Sensor Signal (Analog, Passive) - Test
110-15 Engine Coolant Temperature : High - least severe (1) Coolant Temperature Is High
(continued)
176 UENR4504
(Table 167, contd)

110-16 Engine Coolant Temperature : High - moderate severity (2) Coolant Temperature Is High
152-2 Number Of ECU Resets : Erratic, Intermittent, or Incorrect ECM Memory - Test
Engine Injector Metering Rail #1 Pressure : High - most severe

157-0 Fuel Rail Pressure Problem
(3)
Engine Injector Metering Rail #1 Pressure : Erratic, Intermittent,

or Incorrect
Engine Injector Metering Rail #1 Pressure : Voltage Above
157-3 Sensor Signal (Analog, Active) - Test
Normal
Engine Injector Metering Rail #1 Pressure : Voltage Below
Normal
Engine Injector Metering Rail #1 Pressure : Abnormal Rate of
Change
Engine Injector Metering Rail #1 Pressure : High - moderate se-

verity (2)
Engine Injector Metering Rail #1 Pressure : Low - least severe

(1)
Engine Injector Metering Rail #1 Pressure : Low - moderate se-

verity (2)
166-2 Engine Rated Power : Erratic, Intermittent, or Incorrect ECM Memory - Test
166-14 Engine Rated Power : Special Instruction ECM Memory - Test
168-3 Battery Potential / Power Input #1 : Voltage Above Normal Electrical Power Supply - Test
168-4 Battery Potential / Power Input #1 : Voltage Below Normal Electrical Power Supply - Test
172-3 Engine Air Inlet Temperature : Voltage Above Normal Sensor Signal (Analog, Passive) - Test
172-4 Engine Air Inlet Temperature : Voltage Below Normal Sensor Signal (Analog, Passive) - Test
173-3 Engine Exhaust Gas Temperature : Voltage Above Normal Sensor Signal (Analog, Passive) - Test
173-4 Engine Exhaust Gas Temperature : Voltage Below Normal Sensor Signal (Analog, Passive) - Test
174-3 Engine Fuel Temperature 1 : Voltage Above Normal Sensor Signal (Analog, Passive) - Test
174-4 Engine Fuel Temperature 1 : Voltage Below Normal Sensor Signal (Analog, Passive) - Test
190-8 Engine Speed : Abnormal Frequency, Pulse Width, or Period Speed/Timing - Test
190-15 Engine Speed : High - least severe (1) Engine Overspeeds
Accelerator Pedal #1 Low Idle Switch : Erratic, Intermittent, or

558-2 Idle Validation - Test
Incorrect
This code indicates that an engine idle shutdown is about
593-31 Engine Idle Shutdown has Shutdown Engine
to occur. This code does not represent a fault.
This code indicates that an engine idle shutdown has oc-

594-31 Engine Idle Shutdown Driver Alert Mode
curred. This code does not represent a fault.
623-6 Red Stop Lamp : Current Above Normal Indicator Lamp - Test
624-6 Amber Warning Lamp : Current Above Normal Indicator Lamp - Test
630-2 Calibration Memory : Erratic, Intermittent, or Incorrect Injector Data Incorrect - Test
637-11 Engine Timing Sensor : Other Failure Mode Speed/Timing - Test
639-9 J1939 Network #1 : Abnormal Update Rate CAN Data Link - Test
(continued)
UENR4504 177
(Table 167, contd)

639-14 J1939 Network #1 : Special Instruction CAN Data Link - Test
651-2 Engine Injector Cylinder #01 : Erratic, Intermittent, or Incorrect Injector Data Incorrect - Test
651-5 Engine Injector Cylinder #01 : Current Below Normal Injector Solenoid - Test
651-6 Engine Injector Cylinder #01 : Current Above Normal Injector Solenoid - Test
651-13 Engine Injector Cylinder #01 : Out of Calibration Injector Data Incorrect - Test
676-5 Engine Glow Plug Relay : Current Below Normal Glow Plug Starting Aid - Test
676-6 Engine Glow Plug Relay : Current Above Normal Glow Plug Starting Aid - Test
676-19 Engine Glow Plug Relay : Data Error Glow Plug Starting Aid - Test
677-3 Engine Starter Motor Relay : Voltage Above Normal Relay - Test (Start Relay)
677-5 Engine Starter Motor Relay : Current Below Normal Relay - Test (Start Relay)
677-6 Engine Starter Motor Relay : Current Above Normal Relay - Test (Start Relay)
Engine Speed Sensor #2 : Abnormal Frequency, Pulse Width,

723-8 Speed/Timing - Test
or Period
976-2 PTO Governor State : Erratic, Intermittent, or Incorrect Power Take-Off - Test
1041-2 Start Signal Indicator : Erratic, Intermittent, or Incorrect Relay - Test (Start Relay)
Engine Fuel Injection Pump Fuel Control Valve : Erratic, Inter-

1076-2 Solenoid Valve - Test
Engine Fuel Injection Pump Fuel Control Valve : Current Below

Normal
Engine Fuel Injection Pump Fuel Control Valve : Current Above
Normal
1081-6 Engine Wait to Start Lamp : Current Above Normal Indicator Lamp - Test
This code indicates that the engine will shut down to a long
1109-31 Engine Protection System Approaching Shutdown period at low idle in cold ambient conditions. This code
does not indicate a fault.
Engine Turbocharger 1 Boost Pressure : High - moderate se-
1127-16 Intake Manifold Air Pressure Is High
verity (2)
(continued)
178 UENR4504
(Table 167, contd)

Engine Turbocharger 1 Boost Pressure : Low - moderate se-
1127-18 Intake Manifold Air Pressure Is Low
verity (2)
Engine Turbocharger 1 Wastegate Drive : Current Below

Normal
Engine Turbocharger 1 Wastegate Drive : Current Above
Normal
Sensor Signal (Analog, Active) - Test (Exhaust Gas Pres-
1209-3 Engine Exhaust Gas Pressure : Voltage Above Normal
sure Sensor)
Sensor Signal (Analog, Active) - Test (Exhaust Gas Pres-

1209-4 Engine Exhaust Gas Pressure : Voltage Below Normal
sure Sensor)
1213-6 Malfunction Indicator Lamp (MIL) : Current Above Normal Indicator Lamp - Test
Continuously Monitored Systems Support/Status : Erratic, Inter-

1221-2 ECM Memory - Test
Another diagnostic code has requested engine speed

limitation.
The warning lamp will flash. The engine speed is limited to
Continuously Monitored Systems Support/Status : Special
1221-14 1200 rpm.
Instruction
Troubleshoot all other diagnostic codes. If this code is the
only active diagnostic code, replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”.
1231-9 J1939 Network #2 : Abnormal Update Rate CAN Data Link - Test
1239-0 Engine Fuel Leakage 1 : High - most severe (3) Fuel Rail Pressure Problem
1485-7 ECM Main Relay : Not Responding Properly Relay - Test (ECM Main Relay)
1485-14 ECM Main Relay : Special Instruction Relay - Test (ECM Main Relay)
Aftertreatment 1 Diesel Exhaust Fluid Tank Level : Low - most

1761-1 DEF Tank Level Is Low
severe (3)
Aftertreatment 1 Diesel Exhaust Fluid Tank Level : Not Re-

1761-7 DEF Tank Sensor - Test
sponding Properly
1761-19 Aftertreatment #1 DEF Tank Level : Data Error DEF Tank Sensor - Test
Engine Exhaust Gas Recirculation 1 Mass Flow Rate : Erratic,
2659-2 NRS Mass Flow Rate Problem
Engine Exhaust Gas Recirculation (EGR) Valve Control : Cur-

2791-5 Motorized Valve - Test
rent Below Normal
Engine Exhaust Gas Recirculation (EGR) Valve Control : Cur-
rent Above Normal
Engine Exhaust Gas Recirculation (EGR) Valve Control : Not
Responding Properly
2797-6 Engine Injector Group 1 : Current Above Normal Injector Solenoid - Test
2797-7 Engine Injector Group 1 : Not Responding Properly Injector Solenoid - Test
2798-6 Engine Injector Group 2 : Current Above Normal Injector Solenoid - Test
2840-12 ECU Instance : Failure ECM Memory - Test
2840-14 ECU Instance : Special Instruction Relay - Test (ECM Main Relay)
Mode Selection - Test

Engine Operator Primary Intermediate Speed Select : Erratic,
2880-2 OR
Switch Circuits - Test (Throttle Switch)
(continued)
UENR4504 179
(Table 167, contd)

Engine Operator Primary Intermediate Speed Select : Voltage
2880-3 OR
Above Normal

Engine Operator Primary Intermediate Speed Select : Voltage
2880-4 OR
Below Normal
Accelerator Pedal #2 Low Idle Switch : Erratic, Intermittent, or

2970-2 Idle Validation - Test
Incorrect
Aftertreatment #1 DEF Tank Temperature : Not Responding
Properly
Aftertreatment #1 DEF Tank Temperature : Abnormal Rate of

3031-10 DEF Tank Temperature Is Low
Change
3031-12 Aftertreatment #1 DEF Tank Temperature : Failure DEF Tank Sensor - Test
Aftertreatment #1 DEF Tank Temperature : High - moderate se-

3031-16 DEF Tank Temperature Is High
verity (2)
3216-2 Aftertreatment #1 Intake NOx : Erratic, Intermittent, or Incorrect NOx Sensor - Test
3216-5 Aftertreatment #1 Intake NOx : Current Below Normal NOx Sensor - Test
3216-6 Aftertreatment #1 Intake NOx : Current Above Normal NOx Sensor - Test
3216-10 Aftertreatment #1 Intake NOx : Abnormal Rate of Change NOx Sensor - Test
3216-19 Aftertreatment #1 Intake NOx : Data Error NOx Sensor - Test
3226-2 Aftertreatment #1 Outlet NOx : Erratic, Intermittent, or Incorrect NOx Sensor - Test
3226-5 Aftertreatment #1 Outlet NOx : Current Below Normal NOx Sensor - Test
3226-6 Aftertreatment #1 Outlet NOx : Current Above Normal NOx Sensor - Test
3226-7 Aftertreatment #1 Outlet NOx : Not Responding Properly NOx Sensor - Test
3226-10 Aftertreatment #1 Outlet NOx : Abnormal Rate of Change NOx Sensor - Test
3226-19 Aftertreatment #1 Outlet NOx : Data Error NOx Sensor - Test

3226-21 Aftertreatment #1 Outlet NOx : Data Drifted Low NOx Sensor - Test
Aftertreatment #1 DEF Dosing Unit Input Lines : Not Respond-
3362-7 DEF Pressure Does Not Respond
ing Properly
3363-5 Aftertreatment #1 DEF Tank Heater : Current Below Normal Solenoid Valve - Test (Coolant Diverter Valve)
3363-6 Aftertreatment #1 DEF Tank Heater : Current Above Normal Solenoid Valve - Test (Coolant Diverter Valve)
3509-2 Sensor Supply Voltage 1 : Erratic, Intermittent, or Incorrect Sensor Supply - Test
Aftertreatment #1 DEF Concentration : Erratic, Intermittent, or

3516-2 DEF Concentration Is Incorrect
Incorrect
3516-14 Aftertreatment #1 DEF Concentration : Special Instruction DEF Concentration Is Incorrect
Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : Voltage

Above Normal
Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : Voltage
Below Normal
Aftertreatment 1 Diesel Exhaust Fluid Properties : Voltage Be-
low Normal
(continued)
180 UENR4504
(Table 167, contd)

3520-12 Aftertreatment 1 Diesel Exhaust Fluid Properties : Failure DEF Tank Sensor - Test
3521-19 Aftertreatment #1 DEF Property : Data Error DEF Tank Sensor - Test
Aftertreatment #1 SCR System State : Not Responding

4332-7 DEF Line Heater - Test
Properly
Aftertreatment 1 Diesel Exhaust Fluid Doser Absolute Pressure

4334-0 DEF Pressure Is High
: High - most severe (3)

4334-3 DEF Pump Pressure Sensor - Test
: Voltage Above Normal

4334-4 DEF Pump Pressure Sensor - Test
: Voltage Below Normal

: Not Responding Properly

: Abnormal Rate of Change

4334-16 DEF Pressure Is High
: High - moderate severity (2)

4334-18 DEF Pressure Is Low
: Low - moderate severity (2)

4334-20 DEF Does Not Purge
: Data Drifted High

4334-21 DEF Does Not Purge
: Data Drifted Low
Aftertreatment 1 Diesel Exhaust Fluid Dosing Temperature : Ab-
4337-10 SCR Catalyst Has Incorrect Inlet Temperature
normal Rate of Change
4354-5 Aftertreatment #1 DEF Line Heater #1 : Current Below Normal DEF Line Heater - Test
4354-6 Aftertreatment #1 DEF Line Heater #1 : Current Above Normal DEF Line Heater - Test
4354-12 Aftertreatment #1 DEF Line Heater #2 : Failure Replace the Heater Control Unit (HCU)
4355-5 Aftertreatment #1 DEF Line Heater #2 : Current Below Normal DEF Line Heater - Test
4355-6 Aftertreatment #1 DEF Line Heater #2 : Current Above Normal DEF Line Heater - Test
4355-12 Aftertreatment #1 DEF Line Heater #2 : Failure Replace the Heater Control Unit (HCU)
Aftertreatment #1 SCR Catalyst Intake Gas Temperature : Volt-

4360-3 Sensor Signal (Analog, Passive) - Test
age Above Normal
Aftertreatment #1 SCR Catalyst Intake Gas Temperature : Volt-

age Below Normal
Aftertreatment #1 SCR Catalyst Outlet Gas Temperature : Volt-

age Above Normal
Aftertreatment #1 SCR Catalyst Outlet Gas Temperature : Volt-

age Below Normal
Aftertreatment #1 SCR Catalyst Conversion Efficiency : Low -

4364-17 NOx Conversion Is Low
least severe (1)
Aftertreatment #1 Diesel Exhaust Fluid Pump Motor Speed :

4374-7 DEF Pump - Test
Not Responding Properly
Aftertreatment #1 Diesel Exhaust Fluid Pump Motor Speed : Ab-

(continued)
UENR4504 181
(Table 167, contd)

4374-15 DEF Pressure Is Low
High - least severe

High - moderate severity (2)

Low - moderate severity (2)
Aftertreatment #1 DEF Pump Drive Command : High - moderate

severity (2)
Aftertreatment #1 DEF Pump Drive Command : Low - moderate

severity (2)
4376-5 Aftertreatment #1 DEF Return Valve : Current Below Normal DEF Return Valve - Test
4376-6 Aftertreatment #1 DEF Return Valve : Current Below Normal DEF Return Valve - Test
4377-2 Aftertreatment 1 Outlet NH3 : Erratic, Intermittent, or Incorrect Sensor (Data Link Type) - Test (Ammonia Sensor)
4377-4 Aftertreatment 1 Outlet NH3 : Voltage Below Normal Sensor (Data Link Type) - Test (Ammonia Sensor)
4377-7 Aftertreatment 1 Outlet NH3 : Not Responding Properly Sensor (Data Link Type) - Test (Ammonia Sensor)
4377-12 Aftertreatment 1 Outlet NH3 : Failure Sensor (Data Link Type) - Test (Ammonia Sensor)
4377-19 Aftertreatment 1 Outlet NH3 : Data Error Sensor (Data Link Type) - Test (Ammonia Sensor)
4377-20 Aftertreatment 1 Outlet NH3 : Data Drifted High Sensor (Data Link Type) - Test (Ammonia Sensor)
Aftertreatment 1 Outlet NH3 Gas Sensor Heater Control : Cur-

4383-5 Sensor (Data Link Type) - Test (Ammonia Sensor)
rent Below Normal
Aftertreatment 1 Outlet NH3 Gas Sensor Heater Control : Cur-
rent Above Normal
Aftertreatment 1 Outlet NH3 Gas Sensor Heater Control : Not
Responding Properly
Aftertreatment #1 Diesel Oxidation Catalyst Intake Gas Temper-

Aftertreatment #1 Diesel Oxidation Catalyst Intake Gas Temper-

Aftertreatment 1 Intake NOx Sensor Heater Ratio : Current Be-

5024-5 NOx Sensor - Test
low Normal
Aftertreatment 1 Intake NOx Sensor Heater Ratio : Current
Above Normal
Aftertreatment 1 Intake NOx Sensor Heater Ratio : Not Re-
sponding Properly
Aftertreatment 1 Outlet NOx Sensor Heater Ratio : Current Be-

low Normal
Aftertreatment 1 Outlet NOx Sensor Heater Ratio : Current
Above Normal
Aftertreatment 1 Outlet NOx Sensor Heater Ratio : Not Re-
sponding Properly
5099-6 Engine Oil Pressure Low Lamp Data : Current Above Normal Indicator Lamp - Test
Aftertreatment SCR Operator Inducement Severity : High - most

5245-0 SCR Warning System Problem
severe (3)
Aftertreatment Selective Catalytic Reduction Operator Induce-

5245-6 Indicator Lamp - Test
ment Active : Current Above Normal
(continued)
182 UENR4504
(Table 167, contd)

ment Active : High - least severe (1)

ment Active : High - moderate severity (2)
Aftertreatment SCR Operator Inducement Severity : High - most

severe (3)
Aftertreatment SCR Operator Inducement Severity : High - least

severe (1)
Aftertreatment SCR Operator Inducement Severity moderate

severity (2)
5324-7 Engine Glow Plug 1 : Not Responding Properly Glow Plug Starting Aid - Test
5357-31 Engine Fuel Injection Quantity Error for Multiple Cylinders ECM Memory - Test
Aftertreatment Diesel Exhaust Fluid Dosing Valve : Voltage

5394-3 DEF Injector - Test
Above Normal
Aftertreatment Diesel Exhaust Fluid Dosing Valve : Voltage Be-
low Normal
Aftertreatment Diesel Exhaust Fluid Dosing Valve : Current Be-
low Normal
Aftertreatment Diesel Exhaust Fluid Dosing Valve : Current
Above Normal
Aftertreatment Diesel Exhaust Fluid Dosing Valve : Not Re-
5394-7 DEF Module Does Not Respond
sponding Properly
5419-5 Engine Throttle Actuator #1 : Current Below Normal Motorized Valve - Test
5419-6 Engine Throttle Actuator #1 : Current Above Normal Motorized Valve - Test
5419-7 Engine Throttle Actuator #1 : Not Responding Properly Motorized Valve - Test
5435-5 Aftertreatment #1 DEF Pump State : Current Below Normal DEF Pump - Test
5435-6 Aftertreatment #1 DEF Pump State : Current Above Normal DEF Pump - Test
5435-7 Aftertreatment #1 DEF Pump State : Not Responding Properly DEF Pump - Test
Replace the Diesel Exhaust Fluid (DEF) filter.

Aftertreatment 1 Diesel Exhaust Fluid Pump Orifice Flow : Not
5485-7 Refer to Operation and Maintenance Manual, “Diesel Ex-
Responding Properly
haust Fluid Filter - Clean/Replace”.
Aftertreatment #1 DEF Line Heater Relay : Voltage Above

Normal
Aftertreatment #1 DEF Line Heater Relay : Voltage Below
Normal
Aftertreatment #1 DEF Line Heater Relay : Current Above
Normal
Aftertreatment #1 DEF Line Heater Relay : Not Responding
Properly
5491-19 Aftertreatment #1 DEF Line Heater Relay : Data Error DEF Line Heater - Test
(continued)
UENR4504 183
(Table 167, contd)

High Pressure Common Rail Fuel Pressure Relief Valve : Er-
ratic, Intermittent, or Incorrect
High Pressure Common Rail Fuel Pressure Relief Valve : Not

Responding Properly
High Pressure Common Rail Fuel Pressure Relief Valve : Ab-

High -Pressure Common Rail Fuel Pressure Relief Valve : Spe-

cial Instruction
High Pressure Common Rail Fuel Pressure Relief Valve : High -
Aftertreatment #1 Diesel Exhaust Fluid Pump Heater : Current

Below Normal
Aftertreatment #1 Diesel Exhaust Fluid Pump Heater : Current
Above Normal
5706-12 Aftertreatment #1 Diesel Exhaust Fluid Pump Heater : Failure Replace the Heater Control Unit (HCU)
Aftertreatment #1 Diesel Exhaust Fluid Pump Heater : High -

Aftertreatment #1 Diesel Exhaust Fluid Pump Heater : Low -

Aftertreatment #1 Diesel Exhaust Fluid Pump Heater Command

: High - least severe (1)
Aftertreatment #1 Diesel Exhaust Fluid Pump Heater Command

: Low - least severe (1)
This code indicates that the temperature signal from the

Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Heater Tem- SCR outlet temperature sensor is invalid. Replace the SCR
5798-10
perature : Abnormal Rate of Change outlet temperature sensor. Refer to Disassembly and
Assembly.
Emission Control System Operator Inducement Severity : High -

least severe (1)
Emission Control System Operator Inducement Severity : High -

Diesel Exhaust Fluid Quality Malfunction : Current Above

5841-6 Indicator Lamp - Test
Normal
Aftertreatment #1 DEF Control Module Relay Control : Current
5965-5 Relay - Test (SCR Relay)
Below Normal
Aftertreatment #1 DEF Control Module Relay Control : Current
Above Normal
Aftertreatment #1 DEF Control Module Relay Control : Not Re-
sponding Properly
Aftertreatment #1 DEF Control Module Relay Control : Special

Instruction
184 UENR4504
Diagnostic Functional Tests
Diagnostic Functional
Tests
i05901834
CAN Data Link - Test
Use this procedure if a fault is suspected in the CAN

data link. This procedure also covers the following
diagnostic codes:
Table 168
Diagnostic Trouble Codes for the CAN Data Link

Code
639-9 J1939 Network #1 : Abnormal Update Rate The ECM detects that another controller has incorrectly stopped transmitting a
J1939 speed request (TSC1) or another controller has incorrectly started trans-
mitting a J1939 speed request.
639-14 J1939 Network #1 : Special Instruction Another controller has incorrectly stopped transmitting a signal on the CAN 1 data
link.

The engine limp home strategy will be enabled.
1231-9 J1939 Network #2 : Abnormal Update Rate The ECM has detected that the CAN 2 data link is not functioning.
The following background information is related

to this procedure:
The CAN data link is also known as J1939 data link.
The data link is an industry standard for sending data
between different devices in the same application.
High speed data is transferred via the data link. The
data link cannot be accurately tested without
complicated equipment. The data link requires a
resistance of 60 Ohms between the two wires in order
to transmit the data correctly. This resistance is made
up of two 120 Ohm resistors. The two resistors are
known as “Terminating Resistors” . The terminating
resistors should be at opposite ends of a data link
circuit. If this resistance is not present, then the data
will be intermittent or unreadable.
Note: The wiring for the J1939 data link is a shielded
twisted pair cable. If the wiring is damaged, the
replacement type must be shielded twisted pair cable.
UENR4504 185
Schematic diagram of the CAN 1 datalink
Schematic diagram of the CAN 2 datalink
186 UENR4504
Typical view of the pin locations on the P1 connector
(23) CAN 2 +
(45) CAN 2 -
(46) CAN 1 +
(47) CAN 1 -
UENR4504 187
Table 169
1. Inspect Electrical Connectors and Wiring Damaged Result: A damaged wire or damaged connector was found.
wire or
A. Turn the keyswitch to the OFF position. connector Repair the damaged wire or the damaged connector.
Use the electronic service tool to clear all logged diagnostic
B. Inspect the connectors in the circuit for the CAN data link. codes. Verify that the repair eliminates the fault.
Refer to Troubleshooting, “Electrical Connectors - Inspect” for Result: A damaged wire or damaged connector was not
details. found.
C. Perform a 30 N (6.7 lb) pull test on each of the wires that are as- Proceed to Test Step 2.
sociated with the CAN data link.
D. Check all of the wiring associated with the CAN data link for
abrasions and pinch points.
2. Check the Data Link Terminating Resistance Between 50 Result: The resistance is less than 50 Ohms - there is a
Ohms and 70 short circuit in the harness.
A. Disconnect the P1 connector from the ECM. Ohms
Repair the connectors or the harness and/or replace the con-
B. Measure the resistance between the P1:46 and P1:47. nectors or the harness. Ensure that all of the seals are cor-
rectly in place and ensure that the connectors are correctly
C. Measure the resistance between the P1:23 and P1:45. connected.
Use the electronic service tool in order to clear all logged di-
agnostic codes and then verify that the repair eliminates the
fault.
Result: The resistance is between 110 and 130 Ohms - one

of the terminating resistors may have failed.
One of the terminating resistors is located within the ECM.

Measure the resistance across the two ECM pins for the
CAN data link in order to check this resistor.
Locate the other terminating resistor and remove the termi-
nating resistor from the harness. The terminating resistor
may be located in other ECMs on the data link. Refer to the
Electrical Schematic for the application.
Measure the resistance of the two terminating resistors.
If one of the terminating resistors is incorrect, replace the
faulty terminating resistor.
If the two terminating resistors are between 50 and 70 Ohms
each, proceed to Test Step 4.
Result: The resistance is greater than 150 Ohms.
Result: The resistance is between 50 and 70 Ohms
This is the correct resistance. The fault may be in the con-

nection to other devices on the data link.
(continued)
188 UENR4504
(Table 169, contd)

3. Check the Data Link Wiring Less than 5 Result: At least one of the resistance measurements is
Ohms greater than 5 Ohms - there is an open circuit or high resist-
A. Disconnect each of the connectors that connect other devices ance in the wiring.
on the data link.
Repair the connectors or the harness and/or replace the con-
B. Use a multimeter to measure the resistance between P1:46 and nectors or the harness.
each of the CAN 1 + pins for other devices on the CAN 1 data link. Ensure that all seals are correctly in place and ensure that
Use a multimeter to measure the resistance between P1:23 and the connectors are correctly connected.
each of the CAN 2 + pins for other devices on the CAN 2 data link.
C. Use a multimeter to measure the resistance between P1:46 and agnostic codes and then verify that the repair has eliminated
pin F on the diagnostic connector. the fault.
D. Use a multimeter to measure the resistance between P1:47 and Result: All measured resistances are less than 5 Ohms.
each of the CAN 1 - pins for other devices on the CAN 1 data link.
Use a multimeter to measure the resistance between P1:45 and Proceed to Test Step 4
each of the CAN 2 - pins for other devices on the CAN 2 data link.
E. Use a multimeter in order to measure the resistance between

P1:47 and pin G on the diagnostic connector.
4. Check the Other Devices on the CAN Data Link Other devi- Result: At least one of the other devices is not operating
ces are OK correctly.
A. Use the appropriate service tools in order to diagnose other de-
vices on the data link. Use the appropriate service tools in order to repair other devi-
ces on the data link.
fault.
Result: The other devices are operating correctly.
UENR4504 189
i05919720
DEF Injector - Test

Table 170
Diagnostic Trouble Codes for the DEF Injector

The Electronic Control Module (ECM) detects a short circuit to battery voltage on the pos-
Aftertreatment Diesel Exhaust Fluid itive side of the Diesel Exhaust Fluid (DEF) injector circuit.
5394-3 Dosing Valve : Voltage Above The battery voltage is at least 10 V.
Normal The negative side of the DEF injector circuit does not have an open circuit.
Aftertreatment Diesel Exhaust Fluid The ECM detects a short circuit to ground on the positive side of the DEF injector circuit.
5394-4 Dosing Valve : Voltage Below The battery voltage is at least 10 V.
Normal The warning lamp will flash. The engine will be derated.
The ECM detects an open circuit or a short circuit to ground on the circuit for the DEF in-
Aftertreatment Diesel Exhaust Fluid
jector. This fault is only detected when the DEF injector is not being activated.
5394-5 Dosing Valve : Current Below
Normal
Aftertreatment Diesel Exhaust Fluid The ECM detects a high current condition or short to battery on the circuit for the DEF in-
5394-6 Dosing Valve : Current Above jector. This fault is only detected when the DEF injector is being activated.
DEF Dosing System Accuracy Test

This test is used with the DEF Test Kit to measure the
amount of DEF that the SCR dosing system is
delivering. The test can also be used to confirm that
there is an acceptable spray pattern from the DEF
Injector.
Note: The DEF injector must be removed from the

exhaust system during this test and placed in an
appropriate container. Failure to do so could result in
issues with the SCR system operation. Refer to
Testing and Adjusting, “Aftertreatment SCR System
Dosing Test”.
For the purposes of this procedure, the “DEF Dosing
System Accuracy Test”
Navigate to the following screens in order to access
the “DEF Dosing System Accuracy Test” :
• Diagnostics
• Diagnostic Tests
190 UENR4504
Schematic diagram for the DEF injector circuit
View of the pin locations on the J2 ECM connector for
the DEF injector
(3) DEF injector return
(18) DEF injector supply
UENR4504 191
Table 171
1. Inspect Electrical Connectors and Wiring Damaged Result: A damaged wire or damaged connector was not
wire or found.
A. Check the fuses. connector
B. Inspect the J2/P2 ECM connector.
Result: A damaged wire or damaged connector was found.
C. Inspect the connector for the DEF injector.
Repair the damaged wire or the damaged connector.
D. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM Use the electronic service tool to clear all logged diagnostic
connector and the DEF injector. codes and verify that the repair eliminates the fault.
E. Check all of the wiring associated with the DEF injector for abra-
sions and pinch points.
2. Check for Active Diagnostic Codes Diagnostic Result: A 5394-6 diagnostic code is recently logged.
Trouble
A. Establish communication between the electronic service tool Codes Proceed to Test Step 3.
and the ECM. If necessary, refer to Troubleshooting, “Electronic
Service Tools”. Result: A 5394-5 diagnostic code is active or recently
logged.
Result: A 5394-3 diagnostic code is active or recently

logged.

logged.
3. Create an Open Circuit at the DEF Injector Connector Diagnostic Result: A 5394-5 diagnostic code is not active with the DEF
codes injector disconnected.
The fault is in the wiring between the DEF injector and the
B. Disconnect the connector for the DEF injector. P2 ECM connector.
Replace the faulty wiring.
C. Turn the keyswitch to the ON position. Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.
D. Use the electronic service tool to check for active 5394-5 diag-
nostic codes. Result: A 5394-5 diagnostic code is active with the DEF in-
jector disconnected.
Install a replacement DEF injector. Refer to Disassembly and
Assembly, “DEF Injector and Mounting - Remove and
Install”.
4. Create a Short Circuit at the DEF Injector Connector Less than 5 Result: A 5394-5 diagnostic code is still active with the jump-
Ohms er installed.
B. Disconnect the harness connector from DEF injector. P2 ECM connector.
(continued)
192 UENR4504
(Table 171, contd)

C. Fabricate a jumper wire that is 150 mm (6 inch) long. Use the electronic service tool to clear all logged diagnostic
D. Install the jumper between terminal 1 and terminal 2 on the har-
ness connector for the DEF injector. Result: A 5394-5 diagnostic code is not active with the jump-
er installed.
E. Turn the keyswitch to the ON position.
F. Use the electronic service tool to check for active 5394 diagnos- Assembly, “DEF Injector and Mounting - Remove and
tic codes. Install”.
G. Turn the keyswitch to the OFF position. codes and verify that the repair eliminates the fault.
5. Check the DEF Injector Supply Wiring for a Short to Battery Voltage Result: The measurement indicates voltage on terminal 1 of
the harness connector for the DEF injector.
B. Disconnect the connector for the DEF injector. Disconnect the P2 ECM connector.
P2 connector from the ECM.
Result: There is no voltage present on terminal 1 of the har-
C. Turn the keyswitch to the ON position. ness connector for the DEF injector.
D. Use a multimeter to measure the voltage between terminal 1 on Contact the Dealer Solution Network (DSN).
the harness connector for the DEF injector and a suitable engine
ground.
6. Check the DEF Injector for a Short to Ground Greater than Result: The measured resistance is less than 1 k Ohm.
1 k Ohm
A. Turn the keyswitch to the OFF position. The DEF injector is shorted to ground.
B. Disconnect the connector for the DEF injector. Assembly, “DEF Injector and Mounting - Remove and
Install”.
C. Use a multimeter to measure the resistance between terminal 1 Use the electronic service tool to clear all logged diagnostic
on the DEF injector and engine ground. codes and verify that the repair eliminates the fault.
Result: The measured resistance is greater than 1 k Ohm.
7. Check the DEF Injector Wiring for a Short to Ground Greater than Result: The measured resistance is less than 1 k Ohm.
1 k Ohm
A. Turn the keyswitch to the OFF position. The wiring between the DEF injector and the P2 ECM con-
nector is shorted to ground.
B. Disconnect the P2 connector from the ECM. Replace the faulty wiring.
C. Use a multimeter to measure the resistance between P2:18 and codes and verify that the repair eliminates the fault.
engine ground.
Result: The measured resistance is greater than 1 k Ohm.
UENR4504 193
i05902649
DEF Line Heater - Test

Table 172
Diagnostic Trouble Codes for the DEF Line Heaters

The Electronic Control Module (ECM) detects that the Diesel Exhaust Fluid (DEF) pres-
sure line heater is not effectively heating the DEF.
Aftertreatment #1 SCR System
4332-7 The warning lamp will flash. The engine will be derated.
State : Not Responding Properly
When this diagnostic code is active, check for an associated diagnostic code which could
indicate the cause of the DEF temperature not responding.
This code indicates there is a fault in the DEF suction and return line heater circuit that is
Aftertreatment #1 SCR Catalyst Re- most likely an open circuit.
4354-5 agent Line Heater #1 : Current Be- The battery voltage is at least 10 V.
low Normal The warning lamp will come on.
The warning lamp may flash and the engine may be derated.
This code indicates there is a fault in the DEF suction and return line heater circuit that is
Aftertreatment #1 SCR Catalyst Re-
most likely a short circuit.
4354-6 agent Line Heater #1 : Current
Above Normal
This code indicates there is a fault in the DEF pressure line heater circuit that is most
Aftertreatment #1 SCR Catalyst Re- likely an open circuit.
4355-5 agent Line Heater #2 : Current Be- The battery voltage is at least 10 V.
low Normal The warning lamp will come on.
This code indicates there is a fault in the DEF pressure line heater circuit that is most
Aftertreatment #1 SCR Catalyst Re-
likely a short circuit.
4355-6 agent Line Heater #2 : Current
Above Normal
The ECM detects the voltage to the Heater Control Unit (HCU) is high.
Aftertreatment #1 DEF Line Heater
Relay : Voltage Above Normal
The ECM detects the voltage to the HCU is low.

Relay : Voltage Below Normal
Aftertreatment #1 DEF Line Heater The ECM detects an over temperature fault from the HCU.
5491-5
Relay : Current Below Normal The warning lamp will flash. The engine will be derated.
The ECM detects that the HCU is not responding.

Relay : Not Responding Properly
Aftertreatment #1 DEF Line Heater The ECM has stopped receiving data over the CAN data link from the HCU.
5491-19
Relay : Data Error The warning lamp will come on.
This code indicates there is a fault in the DEF pump heater circuit that is most likely an
Aftertreatment #1 Diesel Exhaust open circuit.
5706-5 Fluid Pump Heater : Current Below The battery voltage is at least 10 V.
Normal The warning lamp will come on.
This code indicates there is a fault in the DEF pump heater circuit that is most likely a
Aftertreatment #1 Diesel Exhaust
short circuit.
5706-6 Fluid Pump Heater : Current Above
Normal
194 UENR4504
The Heater Control Unit (HCU) supplies battery

voltage to the DEF line heaters. If there is a fault on
one of the DEF line heaters, the HCU will send a
diagnostic message to the engine Electronic Control
Module (ECM).
DEF Line Heater Overrides
The electronic service tool can be used to override
each of the three outputs from the HCU individually.
Navigate to the following menus in order to access
the DEF line heater overrides:
• Diagnostics
• Override Parameters
There are three DEF line heater overrides available:
• DEF Pump Heater Override

• DEF Backflow and Suction Line Heater Override
• DEF Pressure Line Heater Override
Schematic diagram of the DEF heater circuit
UENR4504 195
View of the pin locations for the DEF line heaters on
the J1 connector
(23) CAN 2 +
(45) CAN 2 -
View of the pin layout on the HCU
(G1) DEF pump heater
(G2) DEF suction line and return line heater
(G4) DEF pressure line heater
(87) Switched battery (+)
(31) Battery (-)
(DI) CAN 2 (-)
(30) Battery (+)
(ST) CAN 2 (+)
196 UENR4504
Table 173
1. Inspect Electrical Connectors and Wiring Damaged Result: A damaged wire or damaged connector was not
wire or found.
A. Check the fuses. connector
B. Inspect the J1/P1 ECM connector.
Result: A damaged wire or damaged connector was found.
C. Inspect the connectors for the DEF line heaters and the HCU.
D. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM Use the electronic service tool to clear all logged diagnostic
connector, the HCU connector, and the line heaters. codes and verify that the repair eliminates the fault.
E. Check all of the wiring associated with the DEF line heaters for
abrasions and pinch points.
2. Check for Active Diagnostic Codes Diagnostic Result: One of the diagnostic codes listed in Table 172 is
Trouble active.
A. Establish communication between the electronic service tool Codes
and the ECM. If necessary, refer to Troubleshooting, “Electronic Proceed to Test Step 3.
Service Tools”.
Result: A 1231-9 diagnostic code is active.
B. Use the electronic service tool to check for active diagnostic A fault exists on the CAN data link. Troubleshoot this diag-
codes. nostic code before continuing with this procedure. Refer to
Troubleshooting, “CAN Data Link - Test”.
Result: None of the preceding diagnostic codes are active.
If one of the preceding diagnostic codes is recently logged,

an intermittent fault may exist.
Refer to Troubleshooting, “Electrical Connector - Inspect” in
order to identify intermittent faults.
3. Check the Power Supply and Ground for the HCU 10 V to 14 V Result: One of the voltage measurements is not within the
expected range.
There is a fault in the power supply wiring to the HCU.
B. Disconnect the connector for the HCU. Check the fuses. If the fuses are OK, there is an open circuit
in the power supply wiring to the HCU. If a fuse is blown,
C. Turn the keyswitch to the ON position. there may be a short circuit in the power supply wiring to the
HCU.
D. Use a multimeter to measure the voltage between the following
points: Result: Both voltage measurements are not within the ex-
pected range
· Terminal 87 and terminal 31 on the harness connector for the
HCU. The fault is most likely in the ground wiring for the HCU.
Terminal 30 and terminal 31 on the harness connector for the HCU.
Repair the faulty wiring or replace the faulty wiring.
E. Turn the keyswitch to the OFF position. Use the electronic service tool to clear all logged diagnostic
Result: Both voltage measurements are within the expected

range.
4. Check the CAN Data Link for the HCU Less than 5 Result: At least one of the resistance measurements is
Ohms greater than 5 Ohms.
(continued)
UENR4504 197
(Table 173, contd)

B. Disconnect the harness connector from the HCU. Disconnect Replace the wiring between the HCU and the P1 connector
the P1 connector from the ECM. on the ECM.
C. Use a multimeter to measure the resistance between the follow- Use the electronic service tool to clear all logged diagnostic
ing points: codes and verify that the repair eliminates the fault.
· Terminal DI on the harness connector for the HCU and P1:45. Result: Both resistance measurements are less than 5
· Terminal ST on the harness connector for the HCU and P1:23. Ohms.
Reconnect the HCU harness connector and the P1 ECM

connector. Proceed to Test Step 5.
5. Check the Power Supply to the DEF Line Heaters 10 V to 14 V Result: All voltage measurements are within the expected
range.
B. Disconnect the connector for the DEF pressure line, the DEF
suction line, and the DEF pump module. Result: At least one of the voltage measurements is not
within the expected range.
D. Use the electronic service tool to activate the “DEF Pressure Proceed to Test Step 6.
Line Heater Override” .
Use a multimeter to measure the voltage between terminal 1 on the
harness connector for the DEF pressure line heater and a suitable
ground.
E. Use the electronic service tool to deactivate the “DEF Pressure

Line Heater Override” .
F. Disconnect the connector for the DEF suction line heater.
G. Use the electronic service tool to activate the “DEF Backflow

and Suction Line Heater Override” .
Use a multimeter to measure the voltage between terminal 1 on the
harness connector for the DEF suction line heater and a suitable
ground.
H. Use the electronic service tool to deactivate the “DEF Backflow

and Suction Line Heater Override” .
I. Disconnect the connector for the DEF pump module.
J. Use the electronic service tool to activate the “DEF Pump Heater
Override” .
Use a multimeter to measure the voltage between terminal 11 on
the harness connector for the DEF pump module and a suitable
ground.
K. Use the electronic service tool to deactivate the “DEF Pump

Heater Override” .
L. Turn the keyswitch to the OFF position.
6. Check the Wiring Between the HCU and the Line Heaters less than 5 Result: At least one of the resistance measurements is
Ohms greater than 5 Ohms.
Replace the wiring between the HCU and the DEF line
heaters.
(continued)
198 UENR4504
(Table 173, contd)

B. Disconnect the HCU from the harness. Disconnect the connec- Use the electronic service tool to clear all logged diagnostic
tor for the DEF pressure line, the DEF suction line, and the DEF codes and verify that the repair eliminates the fault.
pump module.
Result: All resistance measurements are less than 5 Ohms.
C. Use a suitable multimeter to take the following resistance
measurements: Install a replacement HCU.
·G1 on the HCU harness connector to terminal 11 on the DEF Use the electronic service tool to clear all logged diagnostic
pump module harness connector. codes and verify that the repair eliminates the fault.
·G2 on the HCU harness connector to terminal 1 on the DEF suc-
tion line heater harness connector.
·G4 on the HCU harness connector to terminal 1 on the DEF pres-
sure line heater harness connector.
7. Check the Wiring Between the DEF Suction Line Heater and Less than 5 Result: The measured resistance is greater than 5 Ohms.
the DEF Return Line Heater Ohms
Replace the wiring between the DEF suction line heater and
A. Turn the keyswitch to the OFF position. the DEF return line heater.
B. Disconnect the DEF suction line heater and the DEF return line codes and verify that the repair eliminates the fault.
heater.
Result: The measured resistance is less than 5 Ohms.
C. Use a multimeter to measure the resistance between terminal 2
on the DEF suction line heater harness connector and terminal 1 Proceed to Test Step 8.
on the DEF return line heater harness connector.
8. Check the DEF Line Heaters Continuity Result: At least one of the resistance measurements indi-
cates an open circuit.
Replace the line heater that indicates an open circuit.
B. Disconnect the DEF pressure line heater, the DEF suction line Note: If the suspect heater is the DEF pump heater, the DEF
heater, the DEF return line heater, and the DEF pump module. pump module must be replaced.
C. Use a multimeter to take the following resistance Use the electronic service tool to clear all logged diagnostic
measurements: codes and verify that the repair eliminates the fault.
· Terminal 1 to terminal 2 on each of the DEF line heaters Result: All resistance measurements indicate continuity.
·Terminal 11 to terminal 12 on the DEF pump module
Leave the line heaters disconnected. Proceed to Test Step 9.
9. Check the Ground Connections for the DEF Line Heaters Less than 5 Result: At least one of the resistance measurements is
Ohms greater than 5 Ohms
A. Turn the keyswitch to the OFF position. One of the DEF heaters is not grounded correctly.
B. Use a multimeter to take the following resistance Check the ground connections for the DEF heaters. If neces-
measurements: sary, replace the ground wiring for the DEF heaters.
· Terminal 2 on the DEF pressure line heater harness connector to Result: All resistance measurements are less than 5 Ohms.
a suitable ground
· Terminal 2 on the DEF return line heater harness connector to a Contact the Dealer Solution Network (DSN).
suitable ground
Terminal 12 on the DEF pump module harness connector to a suit-
able ground
UENR4504 199
i05907680
DEF Pump - Test
200 UENR4504
Table 174
Diagnostic Trouble Codes for the DEF Pump

Code
The Electronic Control Module (ECM) detects that the Diesel Exhaust
Fluid (DEF) pump speed is not responding as expected to the speed
Aftertreatment #1 Diesel Exhaust Fluid Pump Motor
4374-7 command from the ECM.
Speed : Not Responding Properly
The ECM has restarted the pump 5 times since the last keyswitch cycle.
The ECM Detects that the DEF pump motor speed has deviated from the
Aftertreatment #1 Diesel Exhaust Fluid Pump Motor
4374-10 required speed between 4.5 and 5.5 seconds.
Speed : Abnormal Rate of Change
The ECM detects that the PWM duty cycle for the DEF pump speed is
Aftertreatment #1 Diesel Exhaust Fluid Pump Motor greater than 86 percent.
4374-16
Speed : High - moderate severity (2) The battery voltage is at least 10 V.
The ECM detects that the PWM duty cycle for the DEF pump speed is
Aftertreatment #1 Diesel Exhaust Fluid Pump Motor less than 4 percent.
4374-18
Speed : Low - moderate severity (2) The battery voltage is at least 10 V.
The ECM detects that the PWM duty cycle for the DEF pump control is
Aftertreatment #1 DEF Pump Drive Command : High - greater than 86 percent.
4375-16
moderate severity (2) The battery voltage is at least 10 V.
The ECM detects that the PWM duty cycle for the DEF pump control is
Aftertreatment #1 DEF Pump Drive Command : Low - less than 4 percent.
4375-18
moderate severity (2) The battery voltage is at least 10 V.
The ECM detects low current condition on the DEF pump motor circuit for
Aftertreatment #1 DEF Pump State : Current Below at least 0.5 seconds.
5435-5
Normal The battery voltage is at least 10 V.
The ECM detects a high current condition on the DEF pump motor circuit
Aftertreatment #1 DEF Pump State : Current Above for at least 0.2 seconds.
5435-6
Normal The SCR relay is closed.
The ECM is unable to communicate with the DEF pump module for three
Aftertreatment #1 DEF Pump State : Not Responding
5435-7 consecutive attempts.
Properly
The ECM detects that the PWM duty cycle for the DEF pump temperature
Aftertreatment #1 Diesel Exhaust Fluid Pump Heater : is greater than 86 percent.
5706-16
High - moderate severity (2) The battery voltage is at least 10 V.
Aftertreatment #1 Diesel Exhaust Fluid Pump Heater : is less than 4 percent.
5706-18
Low - moderate severity (2) The battery voltage is at least 10 V.
Aftertreatment #1 Diesel Exhaust Fluid Pump Heater command signal is greater than 86 percent.
5707-15
Command : High - least severe (1) The battery voltage is at least 10 V.
Aftertreatment #1 Diesel Exhaust Fluid Pump Heater command signal is less than 4 percent.
5707-17
Command : Low - least severe (1) The battery voltage is at least 10 V.
UENR4504 201
Schematic diagram for the DEF pump
202 UENR4504
View of the pin locations on the P1 connector for the
DEF pump
(72) DEF pump motor control signal
(76) DEF pump motor signal feedback
Pin locations on the DEF pump module connector
(2) DEF pump motor control signal/feedback
(4) DEF pump motor (-)
(9) DEF pump motor (+)
DEF Dosing System Verification Test

This test primes the dosing system. The test is used
to ensure that the DEF pump is able to build
adequate pressure.
This test turns on the DEF pump. During this time, the
DEF pump will pressurize the entire DEF dosing
system. The DEF injector will open briefly. The DEF
pump will purge the system at the end of the test.
Navigate to the following menu options in order to
access the “DEF Dosing System Verification Test” :
• Diagnostics
UENR4504 203
Table 175
1. Inspect Electrical Connectors and Wiring Damaged wire or Result: A damaged wire or damaged connector was not
connector found. The fuses are OK
A. Check the fuses.
B. Inspect the P1/J1 ECM connectors.
Result: A damaged wire or damaged connector was
C. Inspect the connector for the DEF pump module. found. A fuse is blown.
D. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM Repair the damaged wire or the damaged connector. Re-
connector and the connector for the DEF pump. place any blown fuses.
Use the electronic service tool to clear all logged diag-
E. Check all of the wiring associated with the DEF pump for abra- nostic codes. Verify that the repair eliminates the fault.
2. Check for Active or Recently Logged Diagnostic Codes Diagnostic Trou- Result: A 4374-7 or 4374-10 diagnostic code is active or
ble Codes recently logged.
Refer to Troubleshooting, “Electronic Service Tools” Proceed to Test Step 3.
B. Look for active or logged diagnostic codes. Result: One of the following diagnostic codes is active or
recently logged:
·4374-16
·4374-18
·4375-16
·4375-18
·5435-5
·5435-6
·5706-16
·5706-18
·5707-15
·5707-17

logged.
3. Check for Frozen DEF Frozen DEF Result: The DEF heaters were not working correctly.
A. If the ambient temperature is below 0° C (32° F), check that the Make any necessary repairs. Refer to Troubleshooting,
DEF heaters are working correctly. Refer to Troubleshooting, “DEF “DEF Line Heater - Test”.
Line Heater - Test”.
Result: The DEF lines are not frozen. The DEF heaters
are working correctly.
Replace the DEF pump module.

nostic codes and verify that the repair eliminates the
fault.
4. Check the Power Supply to the DEF Pump Motor 10 V to 14 V Result: The measured voltage is not within the expected
range.
(continued)
204 UENR4504
(Table 175, contd)

A. Turn the keyswitch to the OFF position. Check the fuse. If the fuse is blown, there may be a short
in the wiring between the DEF pump module and the
B. Disconnect the harness connector for the DEF pump module. SCR relay.
C. Turn the keyswitch to the ON position. Proceed to Test Step 9.
D. Use a multimeter to measure the voltage between terminal 9 on If the fuse is not blown, proceed to Test Step 5.
the harness connector for the DEF pump module and a suitable
ground. Result: The measured voltage is within the expected
range.
5. Check the Wiring Between the DEF Pump Module and the Less than 5 Result: The measured resistance is greater than 5
SCR Relay Ohms Ohms.
A. Turn the keyswitch to the OFF position. The fault is in the wiring between the DEF pump module
and the SCR relay.
B. Disconnect the SCR relay. Replace the faulty wiring.
on the harness connector for the DEF pump module and terminal Result: The measured resistance is less than 5 Ohms.
87 on the harness connector for the SCR relay.
There may be a fault in the circuit for the SCR relay. Refer
to Troubleshooting, “Relay - Test (SCR Relay)” in order to
Troubleshoot this circuit.
Less than 5
6. Check the Ground Wiring for the DEF Pump Motor Ohms Result: The measured resistance is greater than 5
Ohms.
There is a fault in the ground connection for the DEF
B. Use a multimeter to measure the resistance between terminal 4 pump motor.
on the harness connector for the DEF pump module and a suitable Check the ground connections. If necessary, replace the
ground. ground wiring for the DEF pump module.
7. Check the DEF Pump Motor Signal/Feedback Wiring for an Less than 5 Result: At least one of the resistance measurements is
Open Circuit Ohms greater than 5 Ohms.
connector and the P1 ECM connector.
B. Disconnect the DEF pump module connector. Disconnect the Replace the faulty wiring.
P1 connector from the ECM. Proceed to Test Step 9.
C. Use a multimeter to measure the resistance between the follow- Result: Both resistance measurements are less than 5
ing points: Ohms.
· Terminal 2 on the DEF pump module harness connector and Proceed to Test Step 8.
P1:72
· Terminal 2 on the DEF pump module harness connector and
P1:76
(continued)
UENR4504 205
(Table 175, contd)

8. Check the DEF Pump Motor Signal/Feedback Wiring for a Greater than 1 k Result: At least one of the resistance measurements is
Short Circuit Ohm less than 1 k Ohm.
A. Turn the keyswitch to the OFF position. There is a short in the DEF pump signal feedback wiring.
B. Disconnect the P1 connector from the ECM. Proceed to Test Step 9.
C. Use a multimeter to measure the resistance between P1:72 and Result: All resistance measurements are greater than 1
all other terminals on the P1 connector except P1:76. k Ohm.
D. Use a multimeter to measure the resistance between P1:76 and Proceed to Test Step 9.
all other terminals on the P1 connector except P1:72.
9. Run the “ DEF Dosing System Verification Test”” Test Successful Result: The “DEF Dosing System Verification Test”
completed successfully. There are no active diagnostic
A. Turn the keyswitch to the OFF position. codes.
B. Reconnect all electrical connectors and reinstall any DEF lines Return the engine to service.
that may have been removed.
Result: A diagnostic code other than those listed in Table
C. Connect the electronic service tool to the diagnostic connector. 174 is active.
D. Start the engine. Troubleshoot any other diagnostic codes. Refer to Trou-
bleshooting, “Diagnostic Trouble Codes”.
E. Use the electronic service tool to run the “DEF Dosing System
Verification Test” . Result: The “DEF Dosing System Verification Test” was
not successful. One of the diagnostic codes listed in Ta-
F. Check that the “DEF Dosing System Verification Test” com- ble 174 is still active.
pleted successfully and that none of the diagnostic codes listed in
Table 174 are active. Contact the Dealer Solution Network (DSN).
i05921439
DEF Pump Pressure Sensor -

Test
This procedure covers the following diagnostic codes.

Table 176

Code
The Electronic Control Module (ECM) detects that the signal from the Diesel Exhaust Fluid
Aftertreatment #1 SCR Dosing Re-
(DEF) pump pressure sensor is greater than 4.75 V for at least 1 second.
4334-3 agent Absolute Pressure : Voltage
Above Normal
The ECM detects that the signal from the DEF pump pressure sensor is less than 0.25 V
Aftertreatment #1 SCR Dosing Re-
for at least 1 second.
4334-4 agent Absolute Pressure : Voltage
Below Normal
206 UENR4504
Schematic diagram for the DEF pump pressure sensor
View of the pin locations on the P2 ECM connector
for the DEF pump pressure sensor
(5) DEF pump pressure sensor ground
(7) DEF pump pressure sensor supply (+5 V)
(56) DEF pump pressure sensor signal
Pin locations on the DEF pump module connector
(8) DEF pump pressure sensor ground
(9) DEF pump pressure sensor signal
(10) DEF pump pressure sensor supply (+5 V)
UENR4504 207
Table 177
1. Inspect Electrical Connectors and Wiring Damaged wire or Result: A damaged wire or damaged connector
connector was not found.
A. Inspect the P2/J2 ECM connector.
B. Inspect the connector for the DEF pump.
Result: A damaged wire or damaged connector
C. Perform a 30 N (6.7 lb) pull test on each of the wires in the was found.
ECM connector and the connector for the DEF pump.
Repair the damaged wire or the damaged
D. Check all of the wiring associated with the DEF pump for abra- connector.
sions and pinch points. Use the electronic service tool to clear all logged
diagnostic codes. Verify that the repair eliminates
the fault.
2. Check for Active Diagnostic Codes Diagnostic Trouble Result: There is an active or logged , 4334-3 or
Codes 4334-4 diagnostic code.
A. Establish communication between the electronic service tool
and the ECM. Refer to Troubleshooting, “Electronic Service Tools” Proceed to Test Step 3.
B. Check for active or logged codes.
3. Check the Sensor Supply and Ground Wiring 4.9 V to 5.1 V Result: The measured voltage is not within the
expected range.
The fault is in the wiring between the DEF pump
B. Disconnect the DEF pump connector. and the P2 ECM connector.
C. Turn the keyswitch to the OFF position. Proceed to Test Step 5.
D. Use a multimeter to measure the voltage between terminal 8 Result: The measured voltage is within the ex-
and terminal 10 on the harness connector for the DEF pump. pected range.
E. Turn the keyswitch to the OFF position. Proceed to Test Step 4.
4. Check the Voltage on the Sensor Signal Wiring 4.9 V to 5.1 V Result: The measured voltage is not within the
expected range.
The fault is in the wiring between the DEF pump
B. Disconnect the connector for the DEF pump. and the P2 ECM connector.
D. Use a multimeter to measure the voltage between terminal 8 Result: The measured voltage is within the ex-
and terminal 9 on the harness connector for the DEF pump. pected range.
E. Turn the keyswitch to the OFF position. Install a replacement DEF pump module.
Use the electronic service tool to clear all logged
diagnostic codes and verify that the repair elimi-
nates the fault.
5. Perform a DEF Dosing System Verification Test Diagnostic codes Result: The diagnostic code did not return.
A. Start the engine. Return the unit to service.
B. Use the electronic service tool to perform the “DEF Dosing Sys- Result: The diagnostic code returned.
tem Verification Test” .
208 UENR4504

steps are listed.
If the procedure did not correct the issue, Contact the
UENR4504 209
i05910333
DEF Return Valve - Test

Table 178
Diagnostic Trouble Codes for the DEF Return Valve

Code
The Electronic Control Module (ECM) detects a low current condition on
Aftertreatment #1 DEF Return Valve : Current Below the circuit for the DEF purging pump.
4376-5
The Electronic Control Module (ECM) detects a high current condition on

Aftertreatment #1 DEF Return Valve : Current Below the circuit for the DEF purging pump.
4376-6
Schematic diagram for the DEF purging pump
210 UENR4504
View of the pin location on the P2 connector for the
DEF purging pump
(45) DEF purging pump ground
Pin locations on the DEF pump module connector for
the DEF purging pump
(3) DEF purging pump (-)
(5) DEF purging pump (+)
DEF Dosing System Purge Test

This test verifies that the DEF purging process is
working correctly by purging the DEF pump and lines.
This service test is used to purge the DEF system.
This test turns on the DEF purging pump, causing the
DEF to be pumped from the injector back into the
tank. Purging allows the system to de-pressurize and
empty prior to repair work.
Navigate to the following menu options in order to
access the “DEF Dosing System Purge Test” :
• Diagnostics
UENR4504 211
Table 179
A. Check the fuses.
C. Inspect the connector for the DEF pump module. found. A fuse is blown.
connector and the connector for the DEF pump. place any blown fuses.
E. Check all of the wiring associated with the DEF pump for abra- nostic codes. Verify that the repair eliminates the fault.
2. Check for Active or Recently Logged Diagnostic Codes Diagnostic Trou- Result: A 4376-5 diagnostic code is active or recently
ble Codes logged.

B. Look for active or logged diagnostic codes. logged.
3. Check the Power Supply to the DEF Purging Pump 10 V to 14 V Result: The measured voltage is not within the expected
range.
Check the fuse. If the fuse is blown, there may be a short
B. Disconnect the harness connector for the DEF pump module. in the wiring between the DEF pump module and the
SCR relay.
C. Turn the keyswitch to the ON position. Replace the faulty wiring.
D. Use the electronic service tool to activate the “DEF Dosing Sys-
tem Purge Test” . Result: The measured voltage is within the expected
range.
E. Use a multimeter to measure the voltage between terminal 5 on
the harness connector fro the DEF pump and a suitable ground. Proceed to Test Step 5.
4. Check the Wiring Between the DEF Pump Module and the Less than 5 Result: The measured resistance is greater than 5
SCR Relay Ohms Ohms.
and the SCR relay.
B. Disconnect the SCR relay. Replace the faulty wiring.
on the harness connector for the DEF pump module and terminal Result: The measured resistance is less than 5 Ohms.
87 on the harness connector for the SCR relay.
There may be a fault in the circuit for the SCR relay. Refer
to Troubleshooting, “Relay - Test (SCR Relay)” in order to
Troubleshoot this circuit.
Diagnostic codes
5. Create a Short Circuit at the DEF Pump Module Connector
(continued)
212 UENR4504
(Table 179, contd)

A. Turn the keyswitch to the OFF position. Result: The 4376-5 diagnostic code is still active with the
jumper installed.
B. Disconnect the harness connector for the DEF pump module.
The fault is in the wiring between the DEF pump module
C. Fabricate a jumper wire that is 150 mm (6 inch) long. and the ECM.
D. Install the jumper wire between terminal 3 and terminal 5 on the Proceed to Test Step 7.
harness connector for the DEF pump module.
Result: A 4376-6 diagnostic code is active with the jump-
E. Turn the keyswitch to the ON position. er installed.
F. Use the electronic service tool to activate the “DEF Dosing Sys- Install a replacement DEF pump module.
tem Purge Test” . Proceed to Test Step 7.
G. Check for active diagnostic codes.
H. Turn the keyswitch to the OFF position. Remove the jumper

wire.
6. Create an Open Circuit at the DEF Pump Module Connector Diagnostic codes Result: The 4376-6 diagnostic code is still active with the
DEF pump module disconnected.
The fault is in the wiring between the DEF pump module
B. Disconnect the DEF pump module connector. connector and the P1 ECM connector.
D. Use the electronic service tool to activate the “DEF Dosing Sys- Result: A 4376-5 diagnostic code is active with the DEF
tem Purge Test” . pump module disconnected.
E. Check for active diagnostic codes. Install a replacement DEF pump module.
7. Run the “ DEF Dosing System Purge Test”” Diagnostic codes Result: The test completed successfully and there are
no active diagnostic codes.
A. Reconnect all connectors.
B. Turn the keyswitch to the ON position.
Result: The test did not complete successfully. A 4376
C. Use the electronic service tool to run the “DEF Dosing System diagnostic code is active.
Purge Test”
D. Check for active diagnostic codes.
Result: A diagnostic ode other than a 4376 code is
active.
Refer to Troubleshooting, “Diagnostic Trouble Codes” in

order to troubleshoot any other diagnostic codes.
UENR4504 213
i05914177
DEF Tank Sensor - Test

Table 180
Diagnostic Trouble Codes for the DEF Tank Sensor

Code
Aftertreatment 1 Diesel Exhaust Fluid Tank Level : Not The Electronic Control Module (ECM) detects an invalid signal from the
1761-7
Responding Properly Diesel Exhaust Fluid (DEF) tank level sensor for at least 5 seconds.
The ECM detects a loss of signal from the DEF tank level sensor for at
least one second.
1761-19 Aftertreatment #1 DEF Tank Level : Data Error
Aftertreatment #1 DEF Tank Temperature : Not Re- The ECM detects an invalid signal from the DEF tank temperature sensor
3031-7
sponding Properly for at least 5 seconds.
The ECM detects an error message from the DEF tank temperature sen-
sor for at least one second.
3031-12 Aftertreatment #1 DEF Tank Temperature : Failure
The ECM detects a short circuit to battery voltage in the DEF temperature
Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : sensor circuit for at least 2 seconds.
3519-3
Voltage Above Normal The battery voltage is at least 10 V.
The ECM detects a short circuit to ground in the DEF temperature sensor
Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : circuit for at least 2 seconds.
3519-4
Voltage Below Normal The battery voltage is at least 10 V.
The ECM detects a short circuit to battery voltage in the DEF quality sen-
Aftertreatment 1 Diesel Exhaust Fluid Properties : Volt- sor circuit for at least 2 seconds.
3520-4
age Below Normal The battery voltage is at least 10 V.
The ECM detects an error message from the DEF quality sensor for at
Aftertreatment 1 Diesel Exhaust Fluid Properties : least 2 seconds.
3520-12
Failure The battery voltage is at least 10 V.
The ECM detects a loss of signal from the DEF tank sensor unit for at
least one second.
3521-19 Aftertreatment #1 DEF Property : Data Error
214 UENR4504
Schematic diagram for the DEF tank header unit
UENR4504 215
DEF tank header unit.
(23) CAN 2 +
(45) CAN 2 -
View of the connector for the DEF tank header unit
(1) CAN C -
(2) CAN C +
(3) Ground
(4) Battery +
216 UENR4504
Table 181
A. Check the fuses.
C. Inspect the connector for the DEF tank header unit. found. A fuse is blown.
connector and the connector for the DEF tank header unit. place any blown fuses.
E. Check all of the wiring associated with the DEF tank header unit nostic codes. Verify that the repair eliminates the fault.
for abrasions and pinch points.
2. Check for Active or Recently Logged Diagnostic Codes Diagnostic Trou- Result: One or more of the diagnostic codes listed in Ta-
ble Codes ble 180 is active.
Result: There is an active diagnostic code relating to the

B. Look for active or logged diagnostic codes. CAN data link.
Refer to Troubleshooting, “CAN Data Link - Test” before

returning to this procedure.
Result: One or more of the diagnostic codes listed in Ta-

ble 180 is recently logged.
There may be an intermittent fault. Refer to Troubleshoot-

ing, “Electrical Connector - Inspect” in order to identify in-
termittent faults.
3. Check the Power Supply to the Auxiliary Main Relay 10 V to 14 V Result: The measured voltage is not within the expected
range.
There is a fault in the power supply wiring between the
B. Disconnect the auxiliary main relay. auxiliary main relay and battery (+).
C. Turn the keyswitch to the ON position. Use the electronic service tool to clear all logged diag-
D. Use a multimeter to measure the voltage between terminal 30 fault.
on the harness connector for the auxiliary main relay and a suitable
ground. Result: The measured voltage is within the expected
range.
4. Check the Power Supply from the ECM Main Relay 10 V to 14 V Result: The measured voltage is not within the expected
range.
B. Disconnect the auxiliary main relay.
Result: The measured voltage is within the expected
C. Use a multimeter to measure the voltage between terminal 86 range.
on auxiliary main relay and a suitable ground.
(continued)
UENR4504 217
(Table 181, contd)

Less than 5
5. Check the Wiring Between the Auxiliary Main Relay and the Ohms Result: The measured resistance is greater than 5
ECM Main Relay Ohms.
A. Turn the keyswitch to the OFF position. The fault is in the wiring between the auxiliary main relay
and the ECM main relay.
B. Disconnect the auxiliary main relay. Replace the faulty wiring.
C. Disconnect the ECM main relay. nostic codes and verify that the repair eliminates the
fault.
D. Use a multimeter to measure the resistance between terminal
86 on the harness connector for the auxiliary main relay and termi- Result: The measured resistance is less than 5 Ohms.
nal 87 on the harness connector for the ECM main relay.
There may be a fault in the circuit for the ECM main relay.
Refer to Troubleshooting, “Relay - Test (ECM Main Re-
lay)” in order to troubleshoot this circuit.
6. Check the Ground Connections for the Auxiliary Main Relay 10 V to 14 V Result: At least one of the voltage measurements is not
and the DEF Tank Header Unit within the expected range.
A. Turn the keyswitch to the OFF position. Check the ground connections. If necessary, replace the
ground wiring for the auxiliary main relay and the DEF
B. Disconnect the auxiliary main relay. tank header unit.
C. Disconnect the harness connector for the DEF tank header unit. nostic codes and verify that the repair eliminates the
fault.
D. Turn the keyswitch to the ON position.
Result: Both voltage measurements are within the ex-
E. Use a multimeter to measure the voltage between the following pected range.
points:
Reconnect the auxiliary main relay. Proceed to Test Step
· Terminal 30 and terminal 85 on the harness connector for the 7.
relay
· Terminal 30 on the harness connector for the relay and terminal 3
on the harness connector for the DEF tank header unit
7. Check the Power Supply to the DEF Tank Header Unit 10 V to 14 V Result: The measured voltage is not within the expected
range.
B. Disconnect the harness connector for the DEF tank header unit.
Result: The measured voltage is within the expected
C. Turn the keyswitch to the ON position. range.
D. Use a multimeter to measure the voltage between terminal 4 on Proceed to Test Step 9.
the harness connector for the DEF tank header unit and a suitable
ground.
8. Check the Wiring Between the DEF Tank Header Unit and Less than 5 Result: The measured resistance is greater than 5
the Auxiliary Main Relay Ohms Ohms.
A. Turn the keyswitch to the OFF position. Check the fuse. If the fuse is blown there may be a short
in the wiring.
B. Disconnect the harness connector for the DEF tank header unit. If the fuse is OK, there is an open circuit in the wiring.
(continued)
218 UENR4504
(Table 181, contd)

C. Disconnect the auxiliary main relay. Use the electronic service tool to clear all logged diag-
D. Use a multimeter to measure the resistance between terminal 4 fault.
on the harness connector for the DEF tank header unit and termi-
nal 87 on the harness connector for the auxiliary main relay. Result: The measured resistance is less than 5 Ohms.
Install a replacement auxiliary main relay.

fault.
9. Check the CAN Data Link Wiring for the DEF Tank Header Less than 5 Result: At least one of the resistance measurements is
Unit Ohms greater than 5 Ohms.
A. Turn the keyswitch to the OFF position. The fault is in the wiring between the DEF tank header
unit and the P1 ECM connector.
B. Disconnect the harness connector for the DEF tank header unit.
Result: Both resistance measurements are less than 5
C. Disconnect the P1 connector from the ECM. Ohms.
D. Use a multimeter to measure the resistance between the follow- Install a replacement DEF tank header unit.
ing points: Use the electronic service tool to clear all logged diag-
· Terminal 1 on the harness connector for the DEF tank header unit fault.
and P1:45
· Terminal 2 on the harness connector for the DEF tank header unit
and P1:23
If this procedure did not correct the fault, contact the Dealer Solution Network (DSN).
i05915105
ECM Memory - Test

Table 182
Diagnostic Trouble Code for the ECM Memory
152-2 Number Of ECU Resets : Erratic, Intermittent, or Incorrect The software in the Electronic Control Module (ECM) has
reset while the engine was running.
There may be a brief loss of electrical power.

The indicator lamps may come on for 2 seconds (lamp
test).
166-2 Engine Rated Power : Erratic, Intermittent, or Incorrect The ECM has detected an error during a software upgrade.
166-14 Engine Rated Power : Special Instruction The ECM has detected a rating mismatch in the software.
If equipped, the warning lamp will flash and the shutdown

lamp will come on.
The engine will be shut down. The engine will not start.
(continued)
UENR4504 219
(Table 182, contd)

1221-2 Continuously Monitored Systems Support/Status ; Erratic, The ECM continuously monitors the operating conditions of
Intermittent, or Incorrect the engine. If there is an irregularity that is not detected by
the engine sensor diagnostics, this code will become
active.
2840-12 ECU Instance : Failure The ECM detects that the flash file that is installed is
invalid.
5357-31 Engine Fuel Injection Quantity Error for Multiple Cylinders The ECM detects that the number of requested fuel injec-
tions is not compatible with the engine hardware.
No lamps will come on.
220 UENR4504
Table 183
1. Check for Active or Recently Logged Diagnostic Codes Diagnostic Result: A 1221-2 diagnostic code is active or recently
codes logged.
Refer to Troubleshooting, “Electronic Service Tools”. Make a note of all other active or recently logged diagnostic
codes. Troubleshoot all other codes before continuing this
B. Turn the keyswitch to the ON position. If the engine will start, procedure. Refer to Troubleshooting, “Diagnostic Trouble
then run the engine. Codes”.
If 1221-2 is the only active or recently logged diagnostic
C. Monitor the electronic service tool for active and/or recently code, proceed to Test Step 2.
Result: A 152-2 diagnostic code is active or recently logged.
D. Turn the keyswitch to the OFF position.
Make a note of all other active or recently logged diagnostic
codes. Troubleshoot all other codes before continuing this
procedure. Refer to Troubleshooting, “Diagnostic Trouble
Codes”.
If 152-2 is the only active or recently logged diagnostic code,
proceed to Test Step 3.
Result: A 166-X or 2840-12 diagnostic code is active or re-

cently logged.
Check for other active diagnostic codes relating the fuel sys-
tem. Refer to Troubleshooting, “Diagnostic Trouble Codes”.
If there are no other codes relating to the fuel system, pro-
2. Clear the Diagnostic Code and Attempt to Start the Engine 1221-2 diag- Result: The 1221-2 diagnostic code is no longer active.
nostic code
A. Use the electronic service tool to clear the 1221-2 diagnostic Return the engine to service.
code.
Result: The 1221-2 diagnostic code is still active.
B. Turn the keyswitch to the ON position. If the engine will start,
then run the engine for at least 10 minutes. Proceed to Test Step 3.
C. Operate the engine over the full duty cycle in order to replicate
the conditions in which the fault occurred.
D. Stop the engine. Turn the keyswitch to the ON position.
E. Use the electronic service tool to check for an active or recently

logged 1221-2 diagnostic code.
3. Check the Battery Supply Voltage to the ECM Battery Result: The ECM is receiving the correct voltage.
voltage
A. Check that the ECM is receiving the correct battery voltage. Re- Proceed to Test Step 4.
fer to Troubleshooting, “Electrical Power Supply - Test”.
Result: Make any necessary repairs. Refer to Troubleshoot-
ing, “Electrical Power Supply - Test”.
If the diagnostic code is still active, proceed to Test Step 4.
(continued)
UENR4504 221
(Table 183, contd)

4. Re-Flash the ECM Diagnostic Result: The diagnostic code is no longer active.
codes
A. Ensure that the correct rating of flash file for the engine is Use the electronic service tool to clear all logged diagnostic
installed. codes.
B. Ensure that the latest software is installed on the ECM. Refer to
Troubleshooting, “Flash Programming”. Result:The diagnostic code is still active.

codes.
5. Check if a Replacement ECM Eliminates the Fault Diagnostic Result: There are no active diagnostic codes with the re-
codes placement ECM.
A. Contact the Dealer Solution Network (DSN).
Reconnect the suspect ECM. If the fault returns with the sus-
B. If the Dealer Solution Network (DSN) recommends the use of a pect ECM, replace the ECM.
replacement ECM, install a replacement ECM. Refer to Trouble- Use the electronic service tool in order to clear all logged di-
shooting, “Replacing the ECM”. agnostic codes and then verify that the repair eliminates the
fault.
C. Use the electronic service tool to recheck the system for active
diagnostic codes. Result: The diagnostic code is still present with the replace-
ment ECM.
i05956277
Electrical Connector - Inspect The connection of any electrical equipment and

the disconnection of any electrical equipment
may cause an explosion hazard which may result
Most electrical faults are caused by poor connections. in injury or death. Do not connect any electrical
The following procedure will assist in detecting faults equipment or disconnect any electrical equipment
with connectors and with wiring. If a fault is found, in an explosive atmosphere.
correct the condition and verify that the fault is
resolved.
Intermittent electrical faults are sometimes resolved
by disconnecting and reconnecting connectors. It is
very important to check for diagnostic codes
immediately before disconnecting a connector. Also
check for diagnostic codes after reconnecting the
connector. If the status of a diagnostic code is
changed due to disconnecting and reconnecting a
connector, there are several possible reasons. The
likely reasons are loose terminals, improperly
crimped terminals, moisture, corrosion, and
inadequate mating of a connection.
Follow these guidelines:
• Never break the insulation of a wire in order to
access a circuit for measurements. Illustration 58 g01131019
Seal for a three-pin connector (typical example)
• If a wire is cut, always install a new terminal for the
repair.
222 UENR4504
Table 184
1. Check Connectors for Moisture and Corrosion Harness, Result: A fault has been found with the harness or the
connectors, connectors.
A. Inspect all the harnesses. Ensure that the routing of the wiring and seals are
harness allows the wires to enter the face of each connector at a OK. Repair the connectors or the wiring, as required. Ensure that
perpendicular angle. Otherwise, the wire will deform the seal bore. all of the seals are correctly installed. Ensure that the con-
This will create a path for the entrance of moisture. Verify that the nectors have been reattached.
seals for the wires are sealing correctly. If corrosion is evident on the pins, sockets or the connector,
use only denatured alcohol to remove the corrosion. Use a
B. Ensure that the sealing plugs are in place. If any of the plugs are cotton swab or a soft brush to remove the corrosion.
missing, replace the plug. Ensure that the plugs are inserted cor- If moisture was found in the connectors, run the engine for
rectly into the connector. several minutes and check again for moisture. If moisture re-
appears, the moisture is wicking into the connector. Even if
C. Disconnect the suspect connector and inspect the connector the moisture entry path is repaired, it may be necessary to re-
seal. Ensure that the seal is in good condition. If necessary, replace place the wires.
the connector. Use the electronic service tool in order to clear all logged di-
D. Thoroughly inspect the connectors for evidence of moisture fault.
entry. Result: The harness, connectors, and seals are in good
Note: It is normal to see some minor seal abrasion on connector condition.
seals. Minor seal abrasion will not allow the entry of moisture.
If moisture or corrosion is evident in the connector, the source of Proceed to Test Step 2.
the moisture entry must be found and the source of the moisture
entry must be repaired. If the source of the moisture entry is not re-
paired, the fault will recur. Simply drying the connector will not recti-
fy the fault. Check the following items for the possible moisture
entry path:
· Missing seals
· Incorrectly installed seals
· Nicks in exposed insulation
· Improperly mated connectors
Moisture can also travel to a connector through the inside of a wire.
If moisture is found in a connector, thoroughly check the connector
harness for damage. Also check other connectors that share the
harness for moisture.
Note: The ECM is a sealed unit. If moisture is found in an ECM
connector, the ECM is not the source of the moisture. Do not re-
place the ECM.
2. Check the Wires for Damage to the Insulation The wiring is Result: There is damage to the harness.
OK
A. Carefully inspect each wire for signs of abrasion, nicks, and Repair the wires or replace the wires, as required.
cuts. Use the electronic service tool in order to clear all logged di-
Inspect the wires for the following conditions: agnostic codes and then verify that the repair eliminates the
· Exposed insulation fault.
· Rubbing of a wire against the engine
· Rubbing of a wire against a sharp edge Result: The wires are free of abrasion, nicks, and cuts and
the harness is correctly clamped.
B. Check all of the fasteners for the harness and the strain relief
components on the ECM in order to verify that the harness is cor- Proceed to Test Step 3.
rectly secured. Also check all of the fasteners in order to verify that
the harness is not compressed. Pull back the harness sleeves in
order to check for a flattened portion of wire. A fastener that has
been overtightened flattens the harness. This damages the wires
that are inside the harness.
3. Inspect the Connector Terminals Terminals are Result: The terminals of the connector are damaged.
aligned and
undamaged Repair the terminals and/or replace the terminals, as
required.
(continued)
UENR4504 223
(Table 184, contd)

A. Visually inspect each terminal in the connector. Verify that the Use the electronic service tool in order to clear all logged di-
terminals are not damaged. Verify that the terminals are correctly agnostic codes and then verify that the repair eliminates the
aligned in the connector and verify that the terminals are correctly fault.
located in the connector.
Result: The terminals are OK.
A typical example of the lock wedge.
(1) Lock wedge
224 UENR4504
Table 185
4. Perform a Pull Test on Each Wire Terminal Connection Pull test OK Result: A wire has been pulled from a terminal or a terminal
has been pulled from the connector in the 30 N (6.7 lb) pull
A. Ensure that the locking wedge for the connector is installed cor- test.
rectly. Terminals cannot be retained inside the connector if the lock-
ing wedge is not installed correctly. Replace the terminal. Replace damaged connectors, as
required.
B. Perform the 30 N (6.7 lb) pull test on each wire. Each terminal Use the electronic service tool in order to clear all logged di-
and each connector should easily withstand 30 N (6.7 lb) of ten- agnostic codes and then verify that the repair eliminates the
sion and each wire should remain in the connector body. This test fault.
checks whether the wire was correctly crimped in the terminal and Result: All terminals pass the pull test.
whether the terminal was correctly inserted into the connector.
5. Check Individual Pin Retention into the Socket The sockets Result: Terminals are damaged.
provide good
A. Verify that the sockets provide good retention for the pins. Insert retention for Replace the damaged terminals. Verify that the repair elimi-
a new pin into each socket one at a time in order to check for a the new pin. nates the problem.
good grip on the pin by the socket. Use the electronic service tool in order to clear all logged di-
fault.
Result: The terminals are OK.
6. Check the Locking Mechanism of the Connectors The connec- Result: The locking mechanism for the connector is dam-
tors are aged or missing.
A. Ensure that the connectors lock correctly. After locking the con- locked and
nectors, ensure that the two halves cannot be pulled apart. are not Repair the connector or replace the connector, as required.
damaged Use the electronic service tool in order to clear all logged di-
B. Verify that the latch tab of the connector is correctly latched. Also agnostic codes and then verify that the repair eliminates the
verify that the latch tab of the connector returns to the locked fault.
position.
Result: The connectors are in good condition.
Reconnect all connectors. If there are still active diagnostic

codes, refer to Troubleshooting, “Diagnostic Trouble Codes”.
i05915658
Electrical Power Supply - Test
This procedure tests that the correct voltage is being

supplied to the Electronic Control Module (ECM).
This procedure covers the following codes:
UENR4504 225
Table 186
Diagnostic Trouble Codes for the Electrical Power Supply Circuit
168-3 Battery Potential / Power Input 1 : Voltage This code indicates that the battery circuit to the ECM has excessive voltage while the
Above Normal engine is running.
The ECM detects the following conditions:
The battery voltage is high for at least 5 seconds.
The keyswitch is in the ON position.
The engine is not cranking.
168-4 Battery Potential / Power Input 1 : Voltage This code indicates that the battery circuit for the ECM has low voltage while the engine
Below Normal is running.
The battery voltage is low for at least 5 seconds.
The keyswitch is in the ON position.
The ECM will normally log the diagnostic code. If battery voltage disappears without re-
turning, the ECM will not log this diagnostic code and the engine will shut down.
The engine may experience changes in the engine rpm, and intermittent engine shut-
downs or complete engine shutdowns while the conditions that cause this diagnostic
code are present.
Battery+ voltage is supplied through P1: 1, 3, and 5.

The battery- is supplied through P1: 2, 4, and 6. The
ECM receives the keyswitch signal at P1:54 when the
keyswitch is in the ON position or in the START
position. When the ECM detects battery voltage at
this input, the ECM will activate the main relay. When
battery voltage is removed from this input, after a
short time (up to 60 seconds) the ECM will deactivate
the main relay.
The cause of an intermittent power supply to the ECM
can occur on either the positive side or on the
negative side of the battery supply circuit.
Usually, battery power to the diagnostic connector is
available and the battery power to the data link
connector is independent of the keyswitch. Therefore,
although the electronic service tool can be powered
up, there may be no communication with the engine
ECM. The engine ECM requires the keyswitch to be
in the ON position in order to maintain
communications. The ECM may power down a short
time after connecting the electronic service tool if the
keyswitch is in the OFF position.
226 UENR4504
Schematic diagram for the electrical power supply circuit
Not all connectors are shown. Refer to the Electrical Schematic for the application.
electrical power supply circuit
(1) Battery+
(2) Battery ground
(3) Battery+
(4) Battery ground
(5) Battery+
(6) Battery ground
(8) Start Signal
(28) ECM main relay
(54) Ignition key switch
UENR4504 227
Table 187
1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found. A
or connector fuse is blown.
A. Check the fuses.
Repair the damaged wire or the damaged connector. Replace
B. Thoroughly inspect the battery connections and the con- any blown fuses
nections to the relays. Refer to Troubleshooting, “Electrical Use the electronic service tool to clear all logged diagnostic co-
Connector - Inspect” for details. des. Verify that the repair eliminates the fault.
C. Perform a 30 N (6.7 lb) pull test on each of the wires in the Result: All connectors, pins, and sockets are correctly con-
ECM connector that are associated with electrical power sup- nected and/or inserted and the harness is free of corrosion, of
ply circuit. abrasion or of pinch points.
D. Check the harness for abrasion and for pinch points from Proceed to Test Step 2.
the battery to the ECM.
2. Check for Active Diagnostic Codes or Logged Diagnos- Diagnostic Result: There are no active 168 diagnostic codes at this time.
tic Codes codes
If the fault is intermittent, refer to Troubleshooting, “Electrical
A. Connect the electronic service tool to the diagnostic Connector - Inspect”.
connector. If the ECM is receiving no battery voltage, proceed to Test Step
3.
B. Turn the keyswitch to the ON position and start the engine.
Result: There is an active 168-3 diagnostic code.
C. Monitor the active diagnostic code screen on the electronic
service tool. Check and record any active diagnostic codes or Proceed to Test Step 3.
Note: Wait at least 30 seconds in order for the diagnostic co- Result: There is an active 168-4 diagnostic code.
des to become active.
3. Check the Alternator Alternator Result: The alternator is faulty.
A. Test the alternator for correct operation. Refer to Systems Replace the alternator.
Operation, Testing and Adjusting, “Alternator - Test”. Use the electronic service tool to clear all logged diagnostic co-
des and verify that the repair eliminates the fault.
Result: The alternator is operating correctly.
4. Check the Battery Battery load test Result: The battery does not pass the load test. The measured
passed voltage is less than 11 VDC.
A. Load-test the battery. Use a suitable battery load tester. Re-
fer to Systems Operation, Testing and Adjusting, “Battery - Recharge or replace the faulty battery.
Test” for the correct procedure. Use the electronic service tool in order to clear all logged diag-
nostic codes and then verify that the repair eliminates the fault.
Result: The battery passes the load test. The measured volt-
age is at least 11 V.
Check the wiring between the battery and the ECM. Refer to
the Electrical Schematic for the application. Make any neces-
sary repairs.
If the fault is still present, contact the Dealer Solution Network
(DSN).
228 UENR4504
i05916432
Glow Plug Starting Aid - Test

Table 188
Diagnostic Trouble Codes for the Glow Plug Start Aid Circuit

Code
676-5 Engine Glow Plug Relay : Current Below The Electronic Control Module (ECM) detects a low current condition in the control circuit
Normal for the Glow plug Control Unit (GCU) for at least 0.7 seconds.
676-6 Engine Glow Plug Relay : Current Above The ECM detects a high current condition in the control circuit for the GCU for at least
Normal 0.2 seconds.
The ECM will attempt to activate the glow plug control unit for a further five attempts after
the diagnostic code becomes active.
676-19 Engine Glow Plug Relay : Data Error The ECM detects one of the following conditions:
The diagnostic signal from the GCU indicates that there is an error in the GCU.
OR
The diagnostic signal from the GCU is invalid.
5324-7 Engine Glow Plug 1 : Not Responding The ECM detects the following conditions:
Properly
The diagnostic signal from the GCU indicates that there is a short in the circuit for the
glow plug for cylinder number 1.
Properly
Properly
Properly
The following background information is related The GCU transmits a diagnostic signal back to the
to this procedure: engine ECM. If the GCU detects a fault for one of the
glow plugs, a diagnostic code will become active for
The starting aid is used to improve the engine starting that glow plug.
when the engine is cold. With the keyswitch in the ON
position, the Electronic Control Module (ECM) will
monitor the coolant temperature and the engine air
inlet temperature in order to decide if the glow plugs
need to be switched ON. If the glow plugs are
required, then the ECM will activate the glow plug
control unit for a controlled period. While the glow
plug control unit is activated, the glow plug control
unit will supply power to the glow plugs.
Glow plugs are used for temperatures that are below
5° C (41° F).
UENR4504 229
Schematic diagram for the glow plug starting aid circuit
Glow Plug Control unit (GCU)
(22) GCU diagnostic return
(26) GCU control signal
(41) GCU ground
View of the pin locations on the GCU
(1) Glow plug cylinder 3
(3) GCU diagnostic return
(4) Battery +
(5) GCU ground
(8) Glow plug control
Glow Plug Starting Aid Override

Activate this override using the electronic service tool.
This override is used to check that the glow plugs are
functioning correctly. The override will remain active
until switched off using the electronic service tool.
230 UENR4504
Navigate to the following menu options in the

electronic service tool in order to access the “Glow
Plug Starting Aid Override” :
• Diagnostics
• Override Parameters
Table 189
A. Check the fuses.
B. Inspect the terminals on the GCU. Refer to Troubleshoot- any blown fuses
ing, “Electrical Connector - Inspect” for details. Use the electronic service tool to clear all logged diagnostic co-
des. Verify that the repair eliminates the fault.
C. Inspect the connectors between the GCU and the glow
plugs. Result: All connectors, pins, and sockets are correctly con-
nected and/or inserted and the harness is free of corrosion, of
D. Inspect the terminals on the P1/J1 ECM connector and all abrasion or of pinch points.
other connectors associated with the glow plug circuit.
E. Perform a 30 N (6.7 lb) pull test on each of the wires in the
ECM connector that are associated with glow plug circuit.
F. Check the harness for abrasion and for pinch points from
the glow plugs to the GCU, and from the GCU to the ECM.
2. Check for Active Diagnostic Codes or Logged Diagnos- Diagnostic Result: A 5324-7, 5325-7, 5326-7, or 5327-7 diagnostic code is
tic Codes codes active or recently logged.
A. Connect the electronic service tool to the diagnostic Proceed to Test Step 3.
connector.
Result: A 676-XX diagnostic code is active or recently logged
B. Turn the keyswitch to the ON position. Do not start the
engine. Proceed to Test Step 6.
C. Use the electronic service tool to override the glow plug Result: An active diagnostic code or a recently logged diagnos-
start aid. tic code was not displayed.
D. Check for active diagnostic codes or recently logged diag- In order to identify intermittent faults, refer to Troubleshooting,
nostic codes. “Electrical Connector - Inspect”.
E. Use the electronic service tool to turn off the glow plug start
aid.
(continued)
UENR4504 231
(Table 189, contd)

3. Check the Glow Plug for the Suspect Cylinder Resistance Result: The measurement indicates an open circuit between
the glow plug and the ground point.
The glow plug is faulty.
B. Disconnect the connectors for the glow plugs in any sus-
pect cylinders. Refer to Table 188 in order to identify which Replace the suspect glow plug. Refer to Disassembly and As-
cylinders are suspect. sembly, “Glow Plugs - Remove and Install”.
C. Use a multimeter to measure the resistance between the Use the electronic service tool to override the glow plug start
suspect glow plug connector and a suitable engine ground. aid and verify that the repair eliminates the fault. Clear all
Result: The measurement indicates that there is a resistance

between the glow plug and the ground point.
The glow plug is OK.

4. Check the Glow Plug Wiring for an Open Circuit Less than 5 Result: At least one of the resistance measurements is greater
Ohms than 5 Ohms.
The fault is in the wiring between the suspect glow plug and the
B. Disconnect the connectors for any suspect glow plugs. Dis- GCU.
connect the connector for the GCU. Check all wiring between the suspect glow plug and the GCU.
Refer to the Electrical Schematic for the application.
C. Use a multimeter to measure the resistance between the Make any necessary repairs.
harness connector for the suspect glow plug and the appropri-
ate terminal on the GCU connector. Result: All resistance measurements are less than 5 Ohms.
Reconnect all connectors. Proceed to Test Step 5.
5. Check the Glow Plug Wiring for a Short Circuit Greater than 1 k Result: The measured resistance is less than 1 k Ohm.
Ohm
A. Turn the keyswitch to the OFF position. There is a short to ground in the wiring for the suspect glow
plug.
B. Disconnect the connector for the suspect glow plug. Check the wiring between the suspect glow plug and the GCU.
Refer to the Electrical Schematic for the application.
C. Use a multimeter to measure the resistance between the Make any necessary repairs.
harness connector for the suspect glow plug and engine
ground. Result: The measured resistance is greater than 1 k Ohm.
The wiring is OK.

Install a replacement GCU.
Use the electronic service tool to override the glow plug start
aid and verify that the repair eliminates the fault.
(continued)
232 UENR4504
(Table 189, contd)

6. Check that the GCU is Receiving the Correct Voltage 10 V to 14 V Result: The measured voltage is not within the expected
range.
Check the fuse for the GCU. If the fuse is blown, replace the
B. Disconnect the GCU. fuse.
If the fuse is replaced and the fault reoccurs, there is a short in
C. Turn the keyswitch to the ONposition. the wiring between the battery supply and pin 4 on the GCU.
If the fuse is not blown, there is an open circuit in the wiring be-
D. Measure the voltage between pin 4 on the harness connec- tween the battery supply and pin 4 on the GCU.
tor for the GCU and a suitable ground. Repair the faulty wiring or replace the faulty wiring. Reconnect
the GCU. Use the electronic service tool to override the glow
plug start aid and verify that the repair eliminates the fault.
Clear all logged diagnostic codes.
Result: The measured voltage is within the expected range.
7. Check That the GCU is Grounded Correctly 10 V to 14 V Result: The measured voltage is not within the expected
range.
The fault is in the wiring between pin 5 on the harness connec-
B. Disconnect the GCU. tor for the GCU and P1:41.
Inspect the 9-pin engine interface connector. Repair the faulty
C. Turn the keyswitch to the ON position. wiring or replace the faulty wiring. Use the electronic service
tool to override the glow plug start aid and verify that the repair
D. Measure the voltage between pin 4 and pin 5 on the har- eliminates the fault.
ness connector for the GCU. Clear all logged diagnostic codes.
8. Check the Type of Active Diagnostic Code Diagnostic Result: A 676-5 diagnostic code is active
Codes
A. Turn the keyswitch to the ON position. Proceed to Test Step 9.
B. Use the electronic service tool to override the glow plug Result: A 676-6 diagnostic code is active
starting aid.
C. Check for active diagnostic codes.
Result: A 676-19 diagnostic code is active
D. Use the electronic service tool to turn off the glow plug start-
ing aid. Proceed to Test Step 13.
(continued)
UENR4504 233
(Table 189, contd)

9. Create a Short Circuit at the Harness Connector for the Diagnostic Result: A 676-6 diagnostic code is active with the jumper
GCU codes installed.
A. Turn the keyswitch to the OFF position. Install a replacement GCU.

Use the electronic service tool to override the glow plug starting
B. Disconnect the GCU. aid and verify that the repair eliminates the fault.
C. Fabricate a jumper wire that is 15 cm (6 inch) long.
Result: A 676-5 diagnostic code is active with the jumper
D. Install the jumper wire between pin 5 and pin 8 on the har- installed.
ness connector for the GCU.
E. Turn the keyswitch to the ON position.
F. Use the electronic service tool to override the glow plug

starting aid.
G. Check for active diagnostic codes.
H. Use the electronic service tool to turn off the glow plug start-
ing aid.
I. Turn the keyswitch to the OFF position.
J. Remove the jumper wire.
10. Check the Resistance Between the GCU and the ECM Less than 5 Result: The measured resistance is not within the expected
Ohms range.
There is an open circuit or high resistance in the wiring between
B. Disconnect the GCU. Disconnect the P1/J1 connector. pin 8 on the harness connector for the GCU and P1:26.
Inspect the 9-pin engine interface connector. Repair the faulty
C. Measure the resistance between pin 8 on the harness con- wiring or replace the faulty wiring.
nector for the GCU and P1:26.
Result: The measured resistance is within the expected range.
11. Create an Open Circuit at the GCU Harness Connector Diagnostic Result: A 676-5 diagnostic code is active with the GCU
codes disconnected.
Install a replacement GCU.
B. Disconnect the GCU. Use the electronic service tool to override the glow plug starting
aid and verify that the repair eliminates the fault.
C. Turn the keyswitch to the ON position. Clear all logged diagnostic codes.
D. Use the electronic service tool to override the glow plug Result: A 676-6 diagnostic code is active with the GCU
start aid. disconnected.
E. Check for active diagnostic codes. Proceed to Test Step 12.
F. Use the electronic service tool to turn off the glow plug start
aid.
G. Turn the keyswitch to the OFF position.
(continued)
234 UENR4504
(Table 189, contd)

12. Check the GCU control Wire for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is not
Ohm within the expected range.
There is a short circuit in the wiring between the GCU connec-
B. Disconnect the P1/J1 connector. Disconnect the GCU. tor and the P1 ECM connector.
C. Use a multimeter to measure the resistance between P1:26 Use the electronic service tool to clear all logged diagnostic co-
and all other terminals on the P1 connector. des and verify that the repair eliminates the fault.
Result: All resistance measurements are within the expected

range.
13. Check the Diagnostic Return Wire From the GCU Less than 5 Result: The measured resistance is greater than 5 Ohms.
Ohms
A. Turn the keyswitch to the OFF position. There is an open circuit or high resistance in the wiring.
B. Disconnect the GCU. Disconnect the P1/J1 connector.
C. Measure the resistance between pin 3 on the harness con-
nector for the GCU and P1:22. Contact the Dealer Solution Network (DSN).
i05921512
Idle Validation - Test

Table 190

Code
Accelerator Pedal 1 Low Idle Switch : The Electronic Control Module (ECM) detects one of the following conditions:
558-2
Erratic, Intermittent, or Incorrect The signal voltage from the throttle pedal is less than 1.05 V for 0.3 seconds while the idle
validation switch is not active.
Accelerator Pedal 2 Low Idle Switch : The signal voltage from the throttle pedal is greater than 1.25 V for 0.3 seconds while the
2970-2 idle validation switch is active.
Erratic, Intermittent, or Incorrect
If the application is equipped with two throttles, the

engine will use the second throttle until the fault is
repaired.
If a second throttle is not installed or if the second
throttle has a fault, the following conditions will occur:
UENR4504 235
• The engine will default to limp home mode.
• If the engine speed is higher than the speed in limp

home mode, the engine will decelerate to limp
home mode.
• If the engine speed is lower than the speed in limp

home mode, the engine speed will remain at the
current speed.
• The engine will remain at this speed while the

diagnostic code remains active.
• All inputs from the faulty throttle are ignored by the

ECM until the fault is repaired.
• All inputs from the repaired throttle will be ignored
by the ECM until the keyswitch has been cycled.
The IVS may be installed. The IVS is required for
mobile applications. The IVS is part of the throttle
position sensor. The IVS is CLOSED when the low
idle is set.
The configuration parameters for the throttle and for
the IVS thresholds are programmed into the ECM.
Use the electronic service tool in order to display the
configuration parameters for the throttle and for the
IVS.
If the IVS operates outside of the programmed range,
then the engine speed may not respond to changes in
the throttle position.
The electronic service tool may be used for the
following:
• If necessary, reset the IVS threshold for an existing

IVS.
• If necessary, view the IVS change point and reset
the IVS thresholds when a new throttle assembly
is installed.
236 UENR4504
Schematic diagram for the Idle Validation Switch (IVS) switch circuit
IVS circuit
(42) IVS 2
(67) IVS 1
UENR4504 237
Table 191
1. Check for Active Diagnostic Codes Diagnostic Trouble Result: There is an active or logged , 558-2 or
Codes 2970-2 diagnostic code.
and the ECM. Refer to Troubleshooting, “Electronic Service Tools” Proceed to Test Step 2.
B. Check for active or logged codes.
2. Check the Operation of the IVS Switch state Result: The IVS state changes from CLOSED
(ON) to OPEN (OFF).
B. Connect the electronic service tool to the diagnostic connector.
Result: The IVS does not operate
D. Use the electronic service tool in order to check the current
“Throttle Configuration” .
E. Select the “SERVICE” option from the drop-down menu of the

electronic service tool.
F. Select the “Throttle Configuration” option on the electronic

service tool. Select the appropriate “Throttle Configuration” sum-
mary from the menu on the left of the screen. The IVS window for
the throttle will indicate “YES” if an IVS is installed.
G. Select the “Throttle status” function on the electronic service

tool. Select “Status” function and then select “Throttles” function.
H. The throttle is set in the low idle position.
I. Operate the throttle slowly. The IVS status should change from
CLOSED (ON) to OPEN (OFF).
(continued)
238 UENR4504
(Table 191, contd)

3. Check the IVS Threshold Switch operation Result: The IVS switch operates within the “Idle
Validation Min OFF Threshold” and the “Idle Vali-
A. Connect the electronic service tool to the diagnostic connector. dation Max ON Threshold” parameters.
B. Turn the keyswitch to the ON position. The fault appears to be resolved.

C. Use the electronic service tool in order to check the current
“Throttle Configuration” . Result: The IVS switch cannot operate within the
“Idle Validation Min OFF Threshold” and the “Idle
D. Select the “SERVICE” option from the drop-down menu of the Validation Max ON Threshold” parameters
electronic service tool.
E. Select the “Throttle Configuration” option on the electronic
service tool. Select the appropriate “Throttle Configuration” sum-
mary from the menu on the left of the screen. The IVS window for
the throttle will indicate “YES” if an IVS is installed. Make a note
of the “Idle Validation Min OFF Threshold” parameters that are
displayed in the “Throttle Configuration” menu of the electronic
service tool. Make a note of the “Idle Validation Max ON Thresh-
old” parameters that are displayed in the “Throttle Configuration”
menu of the electronic service tool.
F. To select the “Throttle status” function on the electronic service

tool, select “Status” function and then select “Throttles” function.
G. The throttle is set in the low idle position.
H. Operate the throttle slowly. The IVS status should change from
CLOSED (ON) to OPEN (OFF).
A. Inspect the P1/J1 ECM connector.
B. Inspect the connectors for the throttle position sensors.
C. Perform a 30 N (6.7 lb) pull test on each of the wires in the was found.
ECM connector and the connector for the throttle position sensors.
D. Check all of the wiring associated with the throttle position sen- connector.
sors for abrasions and pinch points. Use the electronic service tool to clear all logged
the fault.
5. Check the Voltage at the IVS Switch 7.9 V to 12.2 V Result: The voltage is within the expected range.
A. Disconnect the IVS harness connector. Proceed to Test Step 6.
B. Turn the keyswitch to the ON position. Result: The voltage is not within the expected
range.
C. Use a suitable multimeter to measure the voltage between the
IVS terminal on the harness connector and a suitable ground. Proceed to Test Step 7.
(continued)
UENR4504 239
(Table 191, contd)

6. Check that the IVS is Grounded 7.9 V to 12.2 V Result: The voltage is within the expected range.
A. Disconnect the IVS harness connector. Proceed to Test Step 9.
B. Turn the keyswitch to the ON position. Result: The voltage is not within the expected
range. The fault is in the ground wire for the sus-
C. Use a suitable multimeter to measure the voltage between the pect IVS.
IVS terminal on the harness connector the ground terminal on the
harness connector. Replace the faulty wiring. Refer to the OEM for
more information on the wiring for the IVS.
D. Turn the keyswitch to the OFF position. Use the electronic service tool to clear all logged
nates the fault.
7. Check the Application Harness for an Open Circuit Less than 5 Ohms Result: The measured resistance is less than 5
Ohms.
B. Disconnect the connector for the suspect IVS. Disconnect the
P1 connector. Result: The measured resistance is greater than
5 Ohms.
C. If the IVS 1 is suspect, use a suitable multimeter to measure the
resistance between the IVS terminal on the harness connector to There is an open circuit or high resistance in the
P1:76. wiring between the IVS and the ECM.
If the IVS 2 is suspect, use a suitable multimeter to measure the Replace the faulty wiring.
resistance between the IVS terminal on the harness connector to Use the electronic service tool to clear all logged
P1:42. diagnostic codes and verify that the repair elimi-
nates the fault.
8. Check the Application Harness for a Short Circuit Greater than 1 k Ohm Result: All resistance measurements are greater
than 1 k Ohm.
B. Disconnect the suspect IVS connector. Disconnect the P1
connector. Result: At least one of the measured resistances
is less than 1 k Ohm.
C. If the IVS 1 is suspect, use a suitable multimeter to measure the
resistance between P1:76 and all other terminals on the P1 There is a short in the wiring between the connec-
connector. tor for the suspect IVS and the P1 connector.
If the IVS 2 is suspect, use a suitable multimeter to measure the Replace the faulty wiring.
resistance between P1:42 and all other terminals on the P1 Use the electronic service tool to clear all logged
connector. diagnostic codes and verify that the repair elimi-
nates the fault.
(continued)
240 UENR4504
(Table 191, contd)

9. Check the IVS at the Sensor Less than 10 Ohms at Result: The IVS indicates the expected
low idle. resistance.
Greater than 2000 Ohms No fault is indicated at this time. Recheck the har-
B. Disconnect the IVS. at high idle. ness for intermittent connections.
C. Set the throttle to low idle. Result: At least one of the resistance measure-
ments is outside of the expected range.
D. Check the resistance of the IVS.
Replace the IVS or replace the throttle sensor.
E. Set the throttle to high idle. Refer to OEM documentation for information on
the throttle sensor.
F. Check the resistance of the IVS. Proceed to Test Step 10.
10. Check the IVS Calibration The IVS operates within Result: The IVS operates within the “Idle Valida-
the “Idle Validation Min tion Min OFF Threshold” and the “Idle Validation
A. Connect the electronic service tool to the diagnostic connector. OFF Threshold” and the Max ON Threshold” values that are shown on the
“Idle Validation Max ON “Configuration” menu of the electronic service
B. Turn the keyswitch to the ON position. Threshold” values that tool.
are shown on the “Con-
C. Select the “Throttle Configuration” option on the electronic figuration” menu of the Return the engine to service.
service tool. Select the appropriate “Throttle Configuration” sum- electronic service tool.
mary from the menu on the left of the screen. The IVS window for Result: The IVS does not operate within the “Idle
the throttle will indicate “YES” if an IVS is installed. Make a note Validation Min OFF Threshold” and the “Idle Vali-
of the “Idle Validation Min OFF Threshold” parameters that are dation Max ON Threshold” values that are shown
displayed in the “Throttle Configuration” menu of the electronic on the “Configuration” menu of the electronic
service tool. Make a note of the “Idle Validation Max ON Thresh- service tool.
old” parameters that are displayed in the “Throttle Configuration”
menu of the electronic service tool. Proceed to Test Step 11.
D. Select the “Throttle status” function on the electronic service

tool. Select “Status” function and then select “Throttles” function.
E. Set the throttle to low idle.
F. Operate the throttle slowly toward high idle. The raw percentage
values for the throttle that are shown on the electronic service tool
should increase and the IVS status should change from CLOSED
(ON) to OPEN (OFF) position. Make a note of the raw reading for
the throttle when the IVS reading changes from the CLOSED posi-
tion to the OPEN position. Repeat this step in order to obtain accu-
rate raw percentage values for the throttle. The noted value should
be within the previously noted “Idle Validation Min OFF Threshold”
and “Idle Validation Max ON Threshold” limits.
G. The throttle is set to the full throttle position or the high idle
position.
H. Operate the throttle slowly toward low idle. The raw percentage
values for the throttle that are shown on the electronic service tool
should decrease and the IVS status should change from OPEN
(OFF) to CLOSED (ON) position. Make a note of the raw reading
for the throttle when the IVS reading changes from the OPEN posi-
tion to the CLOSED position. Repeat this step in order to obtain
accurate raw percentage values for the throttle. The noted value
should be within the previously noted “Idle Validation Min OFF
Threshold” and “Idle Validation Max ON Threshold” limits.
Fault cleared
(continued)
UENR4504 241
(Table 191, contd)

11. Use the Electronic Service Tool to Reset the IVS Threshold Result: The fault is cleared after programming
Limits the new calculated values.
The electronic service tool can be used to change the “Idle Valida- Return the engine to service.
tion Min OFF Threshold” and the “Idle Validation Max ON Thresh-
old” in order to suit the type of throttle that is installed. The limits Result: The fault is not cleared.
are shown in the “Throttle Configuration” screen which is located
in the “Service” menu. Contact the Dealer Solution Network (DSN).
A. Refer to Test Step 8 and record the raw value of the throttle sig-
nal when the idle validation switch changes from the CLOSED po-
sition to the OPEN position.
Note: The default value for the “Idle Validation Min OFF Thresh-
old” is 21%. The lowest value that should be set is 5%. The de-
fault value for the “Idle Validation Max ON Threshold” is 25%.
The maximum value that is expected is 28%.
B. Set the “Idle Validation Min OFF Threshold” to 3% below the

raw value that was previously recorded.
C. Set the “Idle Validation Max ON Threshold” to 3% above the

raw value.
D. Enter the new threshold limits into the electronic service tool.
Click “Submit” on the electronic service tool screen.
E. Turn the keyswitch to the OFF position and wait at least 5 sec-
onds. Turn the keyswitch to the ON position.
F. Repeat Test Step 8. Check that the IVS operates within the
newly set threshold limits.

steps are listed.
i05922215
Indicator Lamp - Test
Use this procedure under the following

circumstances:
• The lamps are not receiving battery voltage.

• The lamps are not operating correctly.
• One of the following diagnostic codes is active:
242 UENR4504
Table 192

Code
The Electronic Control Module (ECM) detects a high current condition on the stop lamp cir-
cuit for at least 0.3 seconds.
Red Stop Lamp : Current Above
Normal
The ECM is attempting to activate the lamp.
The ECM detects a high current condition on the warning lamp circuit for at least 0.3
seconds.
Amber Warning Lamp : Current
Above Normal
The ECM detects a high current condition on the wait to start lamp circuit for at least 0.3
seconds.
Engine Wait to Start Lamp : Current
Above Normal
The ECM detects a high current condition on the circuit for the MIL lamp for at least 0.3
seconds.
Malfunction Indicator Lamp (MIL) :
The ECM detects a high current condition on the low oil pressure lamp circuit for at least
0.3 seconds.
Engine Oil Pressure Low Lamp Data
: Current Above Normal
The ECM detects a high current condition on the circuit for the Diesel Exhaust Fluid (DEF)
Aftertreatment Selective Catalytic level lamp for at least 0.3 seconds.
5245-6 Reduction Operator Inducement Ac- The battery voltage is at least 10 V.
tive : Current Above Normal The ECM is attempting to activate the lamp.
The ECM detects a high current condition on the DEF quality lamp circuit for at least 0.3
seconds.
Diesel Exhaust Fluid Quality Mal-
function : Current Above Normal
UENR4504 243
Typical schematic of the circuit for the indicator lamps
Pin locations on the P1 connector for the indicator
lamps
(48) DEF level lamp
(50) Wait to start lamp
(51) Shutdown lamp
(69) Low oil pressure lamp
(74) DEF quality lamp
(92) Warning lamp
(94) MIL lamp
244 UENR4504
Table 193
connector was not found. The fuses are OK.
B. Check the fuses.
C. Thoroughly inspect the P1 connector and the lamp connections. was found. a fuse is blown.
Refer to Troubleshooting, “Electrical Connector - Inspect” for
details. Repair the damaged wire or the damaged con-
nector. Replace any blown fuses.
D. Perform a 30 N (6.7 lb) pull test on each of the wires in the P1 Use the electronic service tool to clear all logged
connector that are associated with the indicator lamps. diagnostic codes. Verify that the repair eliminates
the fault.
E. Check the harness for abrasions and for pinch points from the
battery to the ECM.
2. Check for Recently Logged Diagnostic Codes Diagnostic Trouble Result: At least one of the lamps did not come on
Codes during the lamp test.
Note: Lamp Test When the keyswitch is turned to the ON position, Lamp function Proceed to Test Step 3.
the ECM will activate the lamps for 2 seconds.
Result: One of the diagnostic codes listed in Ta-
B. Check that all of the indicator lamps come on during the 2 sec- ble 192 is active or recently logged.
ond lamp test.
B. Wait at least 10 seconds for activation of the diagnostic codes. Proceed to Test Step 6.
C. Access the “Active Diagnostic Code” screen on the electronic

service tool and check for active diagnostic codes.
3. Check the Lamp Lamp Result: The lamp is OK.
A. Turn the keyswitch to the OFF position. Proceed to Test Step 4.
B. Disconnect the suspect lamp. Inspect the lamp in order to deter- Result: The lamp has failed.
mine if the lamp has failed.
Install a replacement lamp.
C. Use a multimeter in order to measure the resistance across the Turn the keyswitch to the ON position. Ensure that
two terminals of the lamp. If the resistance is more than 2000 the lamp comes on during the 2 second lamp test.
Ohms, the bulb has failed.
4. Measure the Input to the Lamp at the Lamp Socket 10 V to 14 V Result: The measured voltage is within the ex-
pected range.
B. Measure the voltage between the lamp socket and a suitable
ground. Result: The measured voltage is not within the
expected range.
C. Turn the keyswitch to the OFF position.
The fault is in the wiring between the suspect
lamp input and the main relay.
Turn the keyswitch to the ON position. Ensure that
the lamp comes on during the 2 second lamp test.
(continued)
UENR4504 245
(Table 193, contd)

5. Check the Wiring Between the Lamp Connector and the Less than 5 Ohms Result: The measured resistance is greater than
ECM 5 Ohms.
A. Turn the keyswitch to the OFF position. The fault is in the wiring between the suspect
lamp and the P1 ECM connector.
B. Disconnect the suspect lamp. Disconnect the P1 connector. Replace the faulty wiring.
C. Use a suitable multimeter to measure the resistance between the lamp comes on during the 2 second lamp test.
the suspect lamp connector output and the appropriate terminal on
the P1 connector. Refer to Illustration 67 . Result: The measured resistance is less than 5
Ohms.
6. Inspect the Lamp Connector Lamp connector Result: The lamp connector is free from corrosion
and/or damage.
B. Thoroughly inspect the connector for the suspect lamp. Ensure
that the connector is free from corrosion and/or damage. Result: The lamp connector is showing signs of
corrosion and/or damage.
There may be a short in the lamp connector.

Ensure that the connector is free from corrosion.
If necessary, replace the connector.
the lamp comes on during the 2 second lamp test.
8. Check the Wiring Between the Lamp Connector and the Greater than 1 k Ohm Result: At least one of the resistance measure-
ECM for a Short Circuit ments is less than 1 k Ohm.
A. Turn the keyswitch to the OFF position. There is a short in the wiring between the suspect
lamp and the P1 ECM connector.
B. Disconnect the suspect lamp. Disconnect the P1connector from
the ECM. Result: All resistance measurements are greater
than 1 k Ohm.
C. Use a suitable multimeter to measure the resistance between
the terminal for the suspect lamp on the P1 connector and all other Contact the Dealer Solution Network (DSN).
terminals on the P1 connector.

steps are listed.
i05917820
Injector Data Incorrect - Test

246 UENR4504
Table 194
Diagnostic Trouble Codes for “ Injector Data Incorrect””
630-2 Calibration Memory : Erratic, Intermittent, or Incorrect The Electronic Control Module (ECM) detects one of the fol-
lowing conditions.
An injector code has not been programmed for one or more of

the injectors.
OR
The injector code for one or more of the injectors is invalid.
The engine may have rough running at low idle.
651-2 Engine Injector Cylinder #01 : Erratic, Intermittent, or Incorrect The ECM detects that the injector closing time is out of the
specification defined by the injector code.
652-2 Engine Injector Cylinder #02 : Erratic, Intermittent, or Incorrect The warning lamp will come on.
Once the engine has been running for a period of time, the
653-2 Engine Injector Cylinder #03 : Erratic, Intermittent, or Incorrect
ECM will re-calibrate the correct values for the injectors and
654-2 Engine Injector Cylinder #04 : Erratic, Intermittent, or Incorrect the diagnostic code will be cleared.
651-13 Engine Injector Cylinder #01 : Out of Calibration The ECM detects that the injector codes that have been pro-
grammed are from the wrong family of injectors.
652-13 Engine Injector Cylinder #02 : Out of Calibration The warning lamp will come on.
653-13 Engine Injector Cylinder #03 : Out of Calibration
654-13 Engine Injector Cylinder #04 : Out of Calibration

to this procedure:
Injector codes are seven digit alphanumeric codes
that are supplied with each injector. The code is
printed on each injector. The code is used by the
ECM to balance the performance of the injectors.
Refer to Troubleshooting, “Injector Code - Calibrate”
for further information.
Typical example of an electronic unit injector
(1) Location of the injector code
UENR4504 247
Table 195
1. Check That the Correct Injector Codes Have Been Injector codes Result: The injector codes are correct.
Programmed
A. Check that the injector codes that have been programmed
match the codes that are on the injectors. Result: One or more of the injector codes is incorrect.
Refer to Troubleshooting, “Injector Code - Calibrate”.
Use the electronic service tool to program the correct injector
codes.
Refer to Troubleshooting, “Injector Code - Calibrate”.
2. Check for Active Diagnostic Codes Diagnostic Result: One of the following diagnostic codes is active:
codes
A. Connect the electronic service tool to the diagnostic con- · 651-2
nector. Refer to Troubleshooting, “Electronic Service Tools”. · 652-2
· 653-2
B. Turn the keyswitch to the ON position. · 654-2
C. Use the electronic service tool to check for active diagnos- Note: The ECM will learn the correct values in order to clear
tic codes. these diagnostic codes. Only continue with this procedure if the
code has been active for at least 2 hours after the injector code
was programmed.
Result: One of the following diagnostic codes is active:
· 630-2
· 651-13
· 652-13
· 653-13
· 654-13
3. Re-Flash the ECM Diagnostic Result: One of the diagnostic codes listed in Table 194 is still
codes active.
A. Reflash the ECM. Refer to Troubleshooting, “Flash
Programming”. Proceed to Test Step 4.
B. Ensure that all of the injector codes are programmed. Refer Result: None of the diagnostic codes listed in Table 194 are
to Troubleshooting, “Injector Code - Calibrate”. active.
C. Use the electronic service tool to clear all active diagnostic Return the engine to service.
codes.
D. Start the engine.
E. Use the electronic service tool to check for active diagnostic

codes.
(continued)
248 UENR4504
(Table 195, contd)

4. Replace the Suspect Injector Diagnostic Result: The diagnostic code is no longer active.
Codes
A. Replace the injector for the cylinder with the active diagnos- Return the engine to service.
tic code. Refer to Disassembly and Assembly, “Electronic Unit
Injector - Remove” and refer to Disassembly and Assembly, Result: The diagnostic code is still active.
“Electronic Unit Injector - Install”.
B. Use the electronic service tool to input the code for the new
injector. Refer to Troubleshooting, “Injector Code - Calibrate”.
C. Use the electronic service tool to check for active diagnos-

tic codes.
5. Check if a Replacement ECM Eliminates the Fault Diagnostic Result: There are no active diagnostic codes with the replace-
codes ment ECM.
B. If the Dealer Solution Network (DSN) recommends the use pect ECM, replace the ECM.
of a replacement ECM, install a replacement ECM. Refer to Use the electronic service tool in order to clear all logged diag-
Troubleshooting, “Replacing the ECM”. nostic codes and then verify that the repair eliminates the fault.
C. Use the electronic service tool to recheck the system for ac- Result: The diagnostic code is still present with the replace-
tive diagnostic codes. ment ECM.
i05925956
Injector Solenoid - Test

Table 196
Diagnostic Trouble Codes for the Circuit for the Injector Solenoids

Code
651-5 Engine Injector Cylinder #01 : Current These diagnostic codes are designed to indicate an open circuit (low current) in either the
Below Normal solenoid or the wiring for the electronic unit injector in the applicable cylinder.
The Electronic Control Module (ECM) detects the following conditions:
652-5 Engine Injector Cylinder #02 : Current
Below Normal
A low current condition (open circuit) for the applicable cylinder for at least three attempts to
653-5 Engine Injector Cylinder #03 : Current actuate the solenoid.
Below Normal
654-5 Engine Injector Cylinder #04 : Current The engine will have low power and/or rough running.
Below Normal An open circuit will prevent the operation of the electronic unit injector.
(continued)
UENR4504 249
(Table 196, contd)

Diagnostic Trouble Codes for the Circuit for the Injector Solenoids

Code
651-6 Engine Injector Cylinder #01 : Current These diagnostic codes are designed to indicate a short circuit (high current) in either the
Above Normal solenoid or the wiring for the electronic unit injector in the applicable cylinder.
652-6 Engine Injector Cylinder #02 : Current
Above Normal
A high current condition (short circuit) for the applicable cylinder for at least three attempts to
653-6 Engine Injector Cylinder #03 : Current actuate the solenoid.
Above Normal
654-6 Engine Injector Cylinder #04 : Current The engine will have low power and/or rough running.
Above Normal A short circuit will prevent the operation of the electronic unit injector.
2797-6 Engine Injector Group 1 : Current The ECM detects the following conditions:
Above Normal
A short circuit condition in the driver for injector 1 and injector 4.
The fault is present for at least 5 attempts to actuate the driver.
The warning light will flash. The engine will be derated.

The engine will have low power and/or rough running. The engine may shut down.
A short circuit will prevent the operation of the two electronic unit injectors.
2797-7 Engine Injector Group 1 : Not Re- The ECM is unable to actuate any of the injectors.
sponding Properly
The engine will shut down or the engine will be unable to start.
2798-6 Engine Injector Group 2 : Current The ECM detects the following conditions:
Above Normal
A short circuit condition in the driver for injector 2 and injector 3.
The fault is present for at least five attempts to actuate the driver.

The engine will have low power and/or rough running. The engine may shut down.
A short circuit will prevent the operation of the two electronic unit injectors.
250 UENR4504
(1) Cylinder 3 injector supply
(31) Cylinder 3 injector return
Electrical Shock Hazard. The electronic unit injec-

tors use DC voltage. The ECM sends this voltage
to the electronic unit injectors. Do not come in
contact with the harness connector for the elec-
tronic unit injectors while the engine is operating.
Failure to follow this instruction could result in
personal injury or death.
UENR4504 251
Table 197
A. Turn the keyswitch to the OFF position. A strong electrical
shock hazard is present if the keyswitch is not turned OFF. Proceed to Test Step 2.
B. Thoroughly inspect the connectors at the injectors. Refer to Result: A damaged wire or damaged connector
Troubleshooting, “Electrical Connector - Inspect” for details. was found.

C. Perform a 30 N (6.7 lb) pull test on each of the wires in the connector.
ECM connector that are associated with injector solenoids. Use the electronic service tool to clear all logged
the fault.
2. Check for Active Diagnostic Codes Diagnostic Trouble Result: An XXXX-5 diagnostic code is active or
Codes recently logged.
and the ECM. Refer to Troubleshooting, “Electronic Service Tools” Note the cylinders that the codes are applicable
to.
B. Start the engine. Proceed to Test Step 3.
C. Allow the engine to warm up to the normal operating Result: An XXXX-6 diagnostic code is active or
temperature. recently logged.
D. Use the electronic service tool to check for active diagnostic Note the cylinders that the codes are applicable
codes. to.
Make sure that the latest flash file for the applica-
tion is installed in the ECM. Refer to Trouble-
shooting, “Flash Programming”.
Note: This consultation can greatly reduce the re-
pair time.
If the Dealer Solution Network (DSN) recom-
mends the use of a replacement ECM, install a re-
placement ECM. Refer to Troubleshooting,
“Replacing the ECM”.
Start the engine. Wait for at least 30 seconds for
activation of the diagnostic codes.
If the fault is still present with the replacement
ECM installed, contact the Dealer Solution Net-
work (DSN).
Result : None of the diagnostic codes listed in Ta-

ble 196 are active.
There may be an intermittent fault. Refer to Trou-

bleshooting, “Electrical Connector - Inspect” in or-
der to identify intermittent faults.
(continued)
252 UENR4504
(Table 197, contd)

3. Create a Short at the Injector Connector Diagnostic codes Result: An XXX-6 diagnostic code was active
with the jumper installed.
shock hazard is present if the keyswitch is not turned OFF. Thoroughly inspect the electrical connector on the
suspect injector and the harness connector for
B. Disconnect the connector from the suspect injector. the suspect injector. Ensure that the connectors
are free from corrosion. Reconnect the connector
C. Fabricate a jumper wire 100 mm (4 inch) long. for the suspect injector.
Start the engine.
D. Install the jumper wire between terminal 1 and terminal 2 on the If the fault is still present, replace the faulty injec-
harness connector for the suspect injector. tor. Refer to Disassembly and Assembly, “Elec-
tronic Unit Injector - Remove” and Disassembly
E. Start the engine. Wait at least 30 seconds for activation of the and Assembly, “Electronic Unit Injector - Install”.
diagnostic codes. Use the electronic service tool to clear all logged
F. Use the electronic service tool to check for active diagnostic nates the fault.
codes.
Result: An XXX-5 diagnostic code is still present
G. Turn the keyswitch to the OFF position. with the jumper installed.
H. Remove the jumper wire. Proceed to Test Step 4.
4. Create a Short at the 10-Pin Engine Interface Connector Diagnostic codes Result: An XXX-6 diagnostic code is active with
the jumper installed.
shock hazard is present if the keyswitch is not turned OFF. The fault is in the wiring between the injector and
the 10-pin connector.
B. Disconnect the 10-pin connector. Replace the faulty wiring.
C. Fabricate a jumper wire 100 mm (4 inch) long. diagnostic codes and verify that the repair elimi-
nates the fault.
D. Install the jumper wire between the supply and return terminals
for the suspect cylinder on the 10-pin connector on the harness Result: An XXX-5 diagnostic code is still active
between the engine and the ECM. Refer to Illustration 71 for the with the jumper installed.
correct terminals.
E. Start the engine. Wait at least 30 seconds for activation of the
diagnostic codes.
Note: Diagnostic codes for all of the injectors will be active with
the 10-pin connector disconnected. Ignore all other codes and only
look for codes relating to the suspect injector.
F. Use the electronic service tool to check for active diagnostic

codes.
H. Remove the jumper wire.
(continued)
UENR4504 253
(Table 197, contd)

5. Create a Short at the ECM Connector Diagnostic codes Result: An XXX-6 diagnostic code is active with
shock hazard is present if the keyswitch is not turned OFF. The fault is in the wiring for the suspect injector
between the 10-pin connector and the P2
B. Disconnect the P2 connector. connector.
C. Fabricate a jumper wire 100 mm (4 inch) long. Use the electronic service tool to clear all logged
D. Install the jumper wire between the supply and return pins for nates the fault.
the suspect cylinder on the J2 connector. Refer to Illustration 71
for the correct terminals. Result: An XXX-5 diagnostic code is still active
with the jumper installed
E. Turn the keyswitch to the ON position. Wait at least 30 seconds
for activation of the diagnostic codes. Contact the Dealer Solution Network (DSN).
Note: Diagnostic codes for all of the engine sensors will be active
with the P2 connector disconnected. Ignore all other codes and
only look for codes relating to the suspect injector.
F. Use the electronic service tool to check for active diagnostic

codes.
H. Remove the jumper wire.
6. Create an Open Circuit at the Injector Connector or Diagnostic codes Result: An XXX-5 diagnostic code is active with
Connectors the injectors disconnected.
A. Turn the keyswitch to the OFF position. A strong electrical Thoroughly inspect the electrical connector on the
shock hazard is present if the keyswitch is not turned OFF. suspect injector and the harness connector for
the suspect injector. Ensure that the connectors
B. Disconnect the connector for any suspect injectors. are free from corrosion. Reconnect the connector
for the suspect injector.
C. Turn the keyswitch to the ON position. Wait at least 30 seconds Start the engine.
for activation of the diagnostic codes. If the fault is still present, replace the faulty injec-
tor. Refer to Disassembly and Assembly, “Elec-
D. Use the electronic service tool to check for active diagnostic tronic Unit Injector - Remove” and Disassembly
codes. and Assembly, “Electronic Unit Injector - Install”.
E. Turn the keyswitch to the OFF position. diagnostic codes and verify that the repair elimi-
nates the fault.
Result: An XXX-6 diagnostic code is still active

with the injectors disconnected.
(continued)
254 UENR4504
(Table 197, contd)

7. Create an Open Circuit at the 10-Pin Connector Diagnostic codes Result: An XXX-5 diagnostic code is active for
every cylinder.
shock hazard is present if the keyswitch is not turned OFF. The fault is the wiring for the suspect cylinders be-
tween the injector connectors and the 10-pin
B. Disconnect the 10-pin engine interface connector. connector.
C. Turn the keyswitch to the ON position. Wait for at least 30 sec- Use the electronic service tool to clear all logged
onds for activation of the diagnostic codes. diagnostic code and verify that the repair elimi-
nates the fault.
codes. Result: An XXXX-6 diagnostic code is active for
the suspect cylinders.
8. Create an Open Circuit at the ECM Connector Result: An XXX-5 diagnostic code is active with
the P2 connector disconnected.
shock hazard is present if the keyswitch is not turned OFF. The fault is in the wiring between the 10-pin con-
nector and the P2 connector.
B. Disconnect connector P2 from the ECM. Replace the faulty wiring.
Use the electronic service tool in order to clear all
C. Thoroughly inspect the P2 connector. Refer to Troubleshooting, logged diagnostic codes and then verify that the
“Electrical Connectors - Inspect”. repair eliminates the fault.
D. Turn the keyswitch to the ON position. Wait for at least 30 sec- Result: An XXX-6 diagnostic code is still active
onds for activation of the diagnostic codes. with the P2 connector disconnected.
Note: Diagnostic codes for all of the engine sensors will be active
with the P2 connector disconnected. Ignore all other diagnostic co- Contact the Dealer Solution Network (DSN).
des and only look for codes relating to the suspect injectors.
E. Use the electronic service tool to check for active diagnostic

codes.

steps are listed.
UENR4504 255
i05927145

Table 198
Diagnostic Trouble Codes for the Mode Selection Circuit
J1939
Description Notes
Code
2880-2 Engine Operator Primary Intermediate Speed Select : Erratic, In- The Electronic Control Module (ECM) detects the following
termittent, or Incorrect conditions:
The signal voltage from the mode selection switch is between

0.35 V and 4.8 V.
The signal voltage from the mode selection switch is not valid for
any of the available modes for at least 0.5 seconds.
2880-3 Engine Operator Primary Intermediate Speed Select : Voltage The ECM detects the following conditions:
Above Normal
The signal voltage from the mode selection switch is above 4.8
VDC for at least 0.5 seconds.
The battery voltage is at least 10 VDC.
Below Normal
The signal voltage from the mode selection switch is less than
0.35 VDC for at least 0.5 seconds.
The mode selection switch uses resistors to modify

the voltage signal from the ECM. The resistance of
the switch changes dependent on which position the
switch is in. The ECM uses the signal voltage to
determine which mode has been selected.
View of the signal voltage range for the mode selection switch
Note: Position (4) is not available on the mode

selection switch. If the signal voltage range is
between 3.7 and 4.4 VDC, the mode that is selected
will be the same as position (3).
256 UENR4504
Typical example of the schematic for the mode selection switch
for the mode selection switch
(55) Mode selection switch signal
(77) Mode selection switch ground
UENR4504 257
Table 199
connector found.
A. Thoroughly inspect the terminal connections on the P1/J1
B. Thoroughly inspect the connector for the mode selection switch. Result: A damaged wire or damaged connector was
found.
C. Refer to Troubleshooting, “Electrical Connectors - Inspect”.
D. Perform a 30 N (6.7 lb) pull test on each of the wires in the con- Use the electronic service tool to clear all logged diag-
nectors that are associated with the mode selection switch. nostic codes. Verify that the repair eliminates the fault.
switch back to the ECM.
2. Check for Active or Recently Logged Diagnostic Codes Diagnostic Trou- Result: A 2880-4 diagnostic code is active.
ble Codes
B. Connect the electronic service tool to the diagnostic connector. Result: A 2880-3 diagnostic code is active.
C. Turn the keyswitch to the ON position. Do not start the engine. Proceed to Test Step 4.
D. Check for active diagnostic codes with the mode selection Result: A 2880-2 diagnostic code is active.
switch in each position. Wait at least 10 seconds with the switch in
each position for activation of the diagnostic codes. Proceed to Test Step 5.
3. Create an Open Circuit at the Switch Diagnostic codes Result: A 2880-3 diagnostic code is active with the
switch disconnected.
Replace the mode selection switch.
B. Disconnect the mode selection switch. Use the electronic service tool to clear all logged diag-
C. Turn the keyswitch to the ON position. fault.
D. Use the electronic service tool to check for an active 2880 diag- Result: A 2880-4 diagnostic code is still active with the
nostic code. Wait at least 10 seconds for activation of the diagnos- switch disconnected.
tic codes.
Reconnect the switch and proceed to Test Step 7.
4. Create a Short at the Switch Connector Diagnostic codes Result: A 2880-4 diagnostic code is active with the jump-
er installed.
Replace the mode selection switch.
B. Disconnect the mode selection switch. Use the electronic service tool to clear all logged diag-
C. Fabricate a jumper wire and install the jumper wire between the fault.
two harness connector terminals for the mode selection switch.
Result: A 2880-3 diagnostic code is still active with the
D. Turn the keyswitch to the ON position. jumper installed.
E. Use the electronic service tool to check for an active 2880 diag- Reconnect the mode selection switch and proceed to
nostic code. Wait at least 10 seconds for activation of the diagnos- Test Step 7.
tic codes.
(continued)
258 UENR4504
(Table 199, contd)

G. Remove the jumper wire.
5. Check the Voltage at the Switch Connector 4.9 V to 5.1 V Result: The voltage is within the expected range.
A. Turn the keyswitch to the OFF position. Replace the mode selection switch.
B. Disconnect the mode selection switch. nostic codes and verify that the repair eliminates the
fault.
Result: The voltage is not within the expected range.
D. Use a suitable multimeter to measure the voltage between the
signal terminal and the ground terminal at the switch connector. Proceed to Test Step 6.
Less than 5
6. Check the Wiring for High Resistance Ohms Result: At least one of the resistance measurements is
greater than 5 Ohms.
The fault is in the wiring between the switch connector
B. Disconnect the mode selection switch. Disconnect the P1 and the P1 connector.
connector. Replace the faulty wiring.
C. Use a suitable multimeter to measure the resistance between nostic codes and verify that the repair eliminates the
the following points: fault.
·P1:55 to the signal terminal at the switch connector Result: Both resistance measurements are less than 5
·P1:77 to the ground terminal at the switch connector Ohms.
7. Check the Wiring for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is
Ohm less than 1 k Ohm.
There is a short in the wiring between the mode selection
B. Disconnect the P1 connector from the ECM. switch and the P1 connector.
C. Disconnect the mode selection switch. Use the electronic service tool to clear all logged diag-
D. Use a suitable multimeter to measure the resistance between fault.
the following points:
Result: All resistance measurements are greater than 1
·P1:55 and all other terminals on the P1 connector k Ohm.
·P1:77 and all terminals on the P1 connector
i05927289
Motorized Valve - Test

UENR4504 259
Table 200
Diagnostic Trouble Codes for the Motorized Valves

Code
2791-5 Engine Exhaust Gas Recirculation The Electronic Control Module (ECM) detects the following conditions:
(EGR) Valve Control : Current Below
Normal A low current condition in the output for the Exhaust Gas Recirculation (EGR) valve for at least
0.6 seconds.
2791-6 Engine Exhaust Gas Recirculation The ECM detects the following conditions:
(EGR) Valve Control : Current Above
Normal A high current condition in the output for the EGR valve for at least 0.6 seconds.
2791-7 Engine Exhaust Gas Recirculation The ECM detects the following conditions:
(EGR) Valve Control : Not Respond-
ing Properly The signal from the EGR valve position sensor indicates that the valve is not in the desired
position.
This diagnostic code can be caused by a loss of the 5 VDC supply to the EGR valve position
sensor.
5419-5 Engine Throttle Actuator #1 : Current The ECM detects the following conditions:
Below Normal
A low current condition in the output for the engine intake throttle valve for at least 0.6 seconds.
5419-6 Engine Throttle Actuator #1 : Current The ECM detects the following conditions:
Above Normal
A high current condition in the output for the engine intake throttle valve for at least 1 second.
5419-7 Engine Throttle Actuator #1 : Not The ECM detects the following conditions:
Responding Properly
The signal from the intake throttle valve position sensor indicates that the valve is not in the de-
sired position.
This diagnostic code can be caused by a loss of the 5 VDC supply to the intake throttle valve
position sensor.
The engine will be derated. The ECM will log the diagnostic code.
The following background information is related The intake throttle valve is used to increase the
to this procedure: exhaust gas temperature to aid the regeneration
process.
EGR Valve
The EGR valve is used to control the amount of
exhaust gas which is recirculated into the intake
manifold.
The amount of exhaust gas that is required is
calculated by the software that is contained in the
ECM. The EGR valve is controlled by a PWM signal
from the ECM.
Intake Throttle Valve
260 UENR4504
Schematic diagram for the motorized valves

Typical view of the pin locations on the 62-pin engine Typical view of the pin locations on the J2 connector
interface connector for the motorized valves for the motorized valves.
(29) EGR valve PWM signal (8) Intake throttle valve position sensor 5 VDC supply
(30) EGR valve return (9) EGR valve position sensor 5 VDC supply
(33) EGR valve position sensor 5 VDC supply (24) EGR valve position sensor ground
(34) EGR valve position sensor signal (34) Intake throttle valve return
(35) EGR valve position sensor ground (35) EGR valve return
(37) Intake throttle valve PWM signal (37) Intake throttle valve position sensor ground
(38) Intake throttle valve return (39) EGR valve position sensor signal
(41) Intake throttle valve position sensor 5 VDC supply (49) Intake throttle valve PWM signal
(42) Intake throttle valve position sensor signal (50) EGR valve PWM signal
(43) Intake throttle valve position sensor ground (53) Engine intake throttle valve position sensor signal
UENR4504 261
Table 201
1. Inspect Electrical Connectors and Wiring Damaged wire Result: A damaged wire or damaged connector was found.
or connector
A. Thoroughly inspect connectors for the motorized valves. Repair the damaged wire or the damaged connector.
Refer to Troubleshooting, “Electrical Connectors - Inspect” for Use the electronic service tool to clear all logged diagnostic co-
details. des. Verify that the repair eliminates the fault.
B. Thoroughly inspect the P2/J2 ECM connector and the 62- Result: All connectors, pins, and sockets are correctly con-
pin engine interface connector. Refer to Troubleshooting, nected and/or inserted and the harness is free of corrosion, of
“Electrical Connectors - Inspect” for details. abrasion or of pinch points.
C. Perform a 30 N (6.7 lb) pull test on each of the wires that Proceed to Test Step 2.
are associated with the motorized valves.
2. Check for Diagnostic Codes Diagnostic Result: An XXXX-7 diagnostic code is active or recently logged
codes for one or more of the motorized valves
B. Connect the electronic service tool to the diagnostic
connector. Result: An XXXX-5 diagnostic code is active or recently logged
for one or more of the motorized valves.
D. Monitor the electronic service tool for active diagnostic co-
des and/or logged diagnostic codes. Result: An XXXX-6 diagnostic code is active or recently logged
for one or more of the motorized valves.
3. Measure the Sensor Supply Voltage at the Valve 4.9 v to 5.1 V Result: The measured voltage is within the expected range.
Connector
Install a replacement for the suspect valve. Refer to Disassem-
A. Turn the keyswitch to the OFF position. bly and Assembly for more information.
Note: If the EGR valve is replaced, use the electronic service
B. Disconnect the suspect valve from the engine harness. tool to perform the “EGR Valve Learn Reset” .
Use the electronic service tool in order to clear all logged diag-
C. Turn the keyswitch to the ON position. nostic codes and then verify that the repair eliminates the fault.
D. Measure the voltage at the harness connector for the valve Result: The measured voltage is not within the expected
from the 5 V supply terminal of the position sensor to the sen- range.
sor ground terminal.
Reconnect the valve connector. Proceed to Test Step 4.
(continued)
262 UENR4504
(Table 201, contd)

4. Measure the Sensor Supply Voltage at the 62-Pin 4.9 V to 5.1 V Result: The measured voltage is within the expected range.
Connector
The fault is in the 5 VDC supply wire or the ground wire be-
A. Turn the keyswitch to the OFF position. tween the suspect valve and the 62-pin connector.
B. Disconnect the 62-pin connector. Use the electronic service tool to clear all logged diagnostic co-
Result: The measured voltage is not within the expected
D. Measure the voltage at the 62-pin connector on the harness range.
between the engine and the ECM from the 5 VDC sensor sup-
ply terminal for the suspect valve to the sensor ground termi- The fault is in the 5 VDC supply wire or the ground wire be-
nal . tween the ECM and the 62-pin connector.
Use the electronic service tool to clear all logged diagnostic co-
5. Create a Short Circuit at the Valve Connector Diagnostic Result: An XXXX-6 is active with the jumper installed.
codes
A. Turn the keyswitch to the OFF position. Reconnect the valve. Start the engine.
Check for active diagnostic codes on the electronic service tool.
B. Disconnect the connector for the suspect valve. Wait at least 30 seconds in order for the codes to be displayed.
If the XXXX-5 diagnostic code returns, then replace the valve.
C. Fabricate a jumper wire that is 150 mm (6 inch) long. Refer to Disassembly and Assembly for the correct procedure.
Note: If the EGR valve is replaced, use the electronic service
D. Install the jumper between the PWM signal and return pins tool to perform the “EGR Valve Learn Reset” .
on the connector for the suspect valve in order to create a Use the electronic service tool to clear all logged diagnostic co-
short circuit. des and verify that the repair eliminates the fault.
E. Turn the keyswitch to the ON position. Check for active di- Result: An XXXX-5 diagnostic code is still active with the jump-
agnostic codes on the electronic service tool. er installed.
F. Turn the keyswitch to the OFF position. Proceed to Test Step 6.
6. Create a Short Circuit at the 62-Pin Connector Diagnostic Result: An XXXX-6 diagnostic code is active when the jumper
codes is installed.
The fault is in the PWM supply wire or the return wire between
B. Disconnect the 62-pin connector. the suspect valve and the 62-pin connector.
C. Fabricate a jumper wire that is 150 mm (6 inch) long. Install Use the electronic service tool to clear all logged diagnostic co-
the jumper wire between the PWM supply and return terminals des and verify that the repair eliminates the fault.
for the suspect valve on the 62-pin connector on the harness
between the engine and the ECM. Result: An XXXX-5 diagnostic code is still active with the jump-
er installed.
D. Turn the keyswitch to the ON position. Wait at least 30 sec-
onds for activation of the diagnostic codes. Proceed to Test Step 7.
Note: Diagnostic codes for all of the engine sensors will be ac-
tive with the 62-pin connector disconnected. Ignore all other
diagnostic codes and only look for codes that relate to the sus-
pect valve.
E. Look for an active XXXX-6 diagnostic code for the suspect

valve.
F. Remove the jumper wire.
(continued)
UENR4504 263
(Table 201, contd)

7. Create a Short Circuit at the ECM Connector Diagnostic Result: An XXXX-6 diagnostic code was active with the jumper
codes installed.
The fault is in the wiring between the 62-pin engine interface
B. Disconnect the P2 connector from the ECM. connector and the ECM.
the jumper wire between the PWM supply wire and the return des and verify that the repair eliminates the fault.
wire for the suspect valve on the J2 connector.
Result: An XXXX-5 diagnostic code is still active with the jump-
D. Turn the keyswitch to the ON position. Wait at least 30 sec- er installed.
onds for activation of the diagnostic codes.
Note: Diagnostic codes for all of the engine sensors will be ac- Contact the Dealer Solution Network (DSN).
tive with the P2 connector disconnected. Ignore all other co-
des and only look for codes that relate to the suspect valve.
E. Look for an active XXXX-6 diagnostic code for the suspect

valve.
8. Create an Open Circuit at the Valve Connector Diagnostic Result: An XXXX-5 diagnostic code is active with the valve
Codes disconnected.
Reconnect the valve. Start the engine.
B. Disconnect the connector for the suspect valve in order to Check for active diagnostic codes on the electronic service tool.
create an open circuit. Wait at least 30 seconds in order for the codes to be displayed.
If the XXXX-6 diagnostic code returns, then replace the valve.
C. Turn the keyswitch to the ON position. Check for active di- Refer to Disassembly and Assembly for the correct procedure.
agnostic codes on the electronic service tool. Wait at least 30 Note: If the EGR valve is replaced, use the electronic service
seconds in order for the codes to be displayed. tool to perform the “EGR Valve Learn Reset” .
Result: An XXXX-6 diagnostic code is still active with the valve

disconnected.
(continued)
264 UENR4504
(Table 201, contd)

9. Create an Open Circuit at the 62-Pin Connector Diagnostic Result: An XXXX-5 diagnostic code is active with the 62-pin
codes connector disconnected.
The fault is in the wiring between the suspect valve and the 62-
B. Disconnect the 62-pin connector. pin connector.
C. Turn the keyswitch to the ON position. Wait at least 30 sec- Use the electronic service tool to clear all logged diagnostic co-
onds for activation of the diagnostic codes. des and verify that the repair eliminates the fault.
tive with the 62-pin connector disconnected. Ignore all other Result: An XXXX-6 diagnostic code is still active with the 62-
codes and only look for codes that relate to the suspect valve. pin connector disconnected.
D. Check for an active XXXX-5 diagnostic code for the sus- Proceed to Test Step 10.
pect valve.
10. Create an Open Circuit at the ECM Connector Diagnostic Result: An XXXX-5 diagnostic code is active with the P2 con-
codes nector disconnected.
The fault is in the wiring between the suspect valve and the
B. Disconnect the P2 connector. ECM P2 connector.
tive with the P2 connector disconnected. Ignore all other diag- Result: An XXXX-6 diagnostic code is still active with the P2
nostic codes and only look for codes that relate to the suspect connector disconnected.
valve.
D. Check for an active XXXX-5 diagnostic code for the sus-
pect valve.
i05933421
NOx Sensor - Test

Table 202
Diagnostic Trouble Codes for the NOx Sensors

3216-2 Aftertreatment #1 Intake NOx : Er- The Electronic Control Module (ECM) detects one of the following conditions:
ratic, Intermittent, or Incorrect The signal from the engine out NOx sensor is invalid.
The sensor supply to the engine out NOx sensor is faulty.
The warning lamp may flash. The engine may be derated.
3216-5 Aftertreatment #1 Intake NOx : Cur- The ECM detects an open circuit error message from the engine out NOx sensor for at least
rent Below Normal 2 seconds.
3216-6 Aftertreatment #1 Intake NOx : Cur- The ECM detects a short circuit error message from the engine out NOx sensor for at least 2
rent Above Normal seconds.
(continued)
UENR4504 265
(Table 202, contd)

Diagnostic Trouble Codes for the NOx Sensors

3216-10 Aftertreatment #1 Intake NOx : Ab- The ECM detects that the difference between the oxygen signal from the engine out NOx
normal Rate of Change sensor and the calculated oxygen level is to great.
3216-19 Aftertreatment #1 Intake NOx : Da- The ECM detects a loss of communication with the engine out NOx sensor for at least 0.5
ta Error seconds.
3226-2 Aftertreatment #1 Outlet NOx : Er- The ECM detects one of the following conditions:
ratic, Intermittent, or Incorrect The signal from the tailpipe out NOx sensor is invalid.
The sensor supply to the tailpipe out NOx sensor is faulty.
The warning lamp may flash. The engine may be derated.
3226-5 Aftertreatment #1 Outlet NOx : Cur- The ECM detects an open circuit error message from the tailpipe out NOx sensor for at least
rent Below Normal 2 seconds.
3226-6 Aftertreatment #1 Outlet NOx : Cur- The ECM detects a short circuit error message from the tailpipe out NOx sensor for at least
rent Above Normal 2 seconds.
3226-7 Aftertreatment #1 Outlet NOx : Not The ECM detects that the amount of NOx measured by the tailpipe out NOx sensor does not
Responding Properly vary enough to be a plausible signal
3226-10 Aftertreatment #1 Outlet NOx : Ab- The ECM detects that the difference between the oxygen signal from the tailpipe out NOx
normal Rate of Change sensor and the calculated oxygen level is to great.
3226-19 Aftertreatment #1 Outlet NOx : Da- The ECM detects a loss of communication with the tailpipe out NOx sensor for at least 0.5
ta Error seconds.
3226-21 Aftertreatment #1 Outlet NOx : Da- The ECM detects a negative value for the NOx signal from the engine out NOx sensor.
ta Drifted Low The warning lamp will flash. The engine will be derated.
5024-5 Aftertreatment 1 Intake NOx Sen- The ECM detects an open circuit error message for the heater circuit on the engine out NOx
sor Heater Ratio : Current Below sensor for at least 2 seconds.
5024-6 Aftertreatment 1 Intake NOx Sen- The ECM detects a short circuit error message for the heater circuit on the engine out NOx
sor Heater Ratio : Current Above sensor for at least 2 seconds.
5024-7 Aftertreatment 1 Intake NOx Sen- The ECM detects that the engine out NOx sensor has not reached operating temperature
sor Heater Ratio : Not Responding after 3 minutes of heater operation.
Properly The warning lamp will come on.
5031-5 Aftertreatment 1 Outlet NOx Sen- The ECM detects an open circuit error message for the heater circuit on the tailpipe out NOx
sor Heater Ratio : Current Below sensor for at least 2 seconds.
5031-6 Aftertreatment 1 Outlet NOx Sen- The ECM detects a short circuit error message for the heater circuit on the tailpipe out NOx
sor Heater Ratio : Current Above sensor for at least 2 seconds.
5031-7 Aftertreatment 1 Outlet NOx Sen- The ECM detects that the engine out NOx sensor has not reached operating temperature
sor Heater Ratio : Not Responding after 3 minutes of heater operation.
266 UENR4504
Schematic diagram for the NOx sensors
Note: The “ADDRESS” wire that is connected to the

engine out NOx sensor is used by the ECM to
differentiate the signal from the engine out NOx
sensor and the tailpipe out NOx sensor.
NOx sensors.
(23) J1939 CAN 2 +
(45) J1939 CAN 2 -
UENR4504 267
Table 203
A. Check the fuses.
B. Thoroughly inspect the connectors for the NOx sensors. any blown fuses.
Refer to Troubleshooting, “Electrical Connector - Inspect” for Use the electronic service tool to clear all logged diagnostic co-
C. Thoroughly inspect the P1/J1 ECM connector . Refer to Result: All connectors, pins, and sockets are correctly con-
Troubleshooting, “Electrical Connector - Inspect” for details. nected and/or inserted and the harness is free of corrosion, of
abrasion or of pinch points. The fuses are OK.
D. Perform a 30 N (6.7 lb) pull test on each of the wires that
are associated with the NOx sensors. Proceed to Test Step 2.
2. Check for Diagnostic Codes Diagnostic Result: A diagnostic code other than those listed in Table 202
codes is active or recently logged.
Troubleshoot the other diagnostic codes before returning to this
B. Connect the electronic service tool to the diagnostic procedure. Refer to Troubleshooting, “Diagnostic Trouble
connector. Codes”.
C. Turn the keyswitch to the ON position. Result: One of the diagnostic listed in Table 202 is active or re-
cently logged.
des and/or logged diagnostic codes. Proceed to Test Step 3.
Result: None of the diagnostic codes listed in Table 202 are

active or recently logged.
The fault may be intermittent. Refer to Troubleshooting, “Electri-

cal Connector - Inspect” in order to identify intermittent faults.
3. Inspect the Exhaust System for Leaks Exhaust leaks Result: There is a leak in the exhaust system.
A. Thoroughly inspect the exhaust system for leaks. Refer to Make any necessary repairs.
Systems Operation, Testing and Adjusting, “Air Inlet and Ex- Run the engine. Use the electronic service tool in order to clear
haust System - Inspect”. all logged diagnostic codes and then verify that the repair elimi-
nates the fault.
4. Inspect the NOx Sensors NOx sensors Result: Fault found with the NOx sensors.
A. Inspect the NOx sensors for damage. Make any necessary repairs. If necessary, replace a damaged
NOx sensor. Refer to Disassembly and Assembly, “Nitrogen
B. Check that the NOx sensors are mounted in the correct Oxide Sensor - Remove and Install” for the correct procedure.
position. Run the engine. Use the electronic service tool to clear all
logged diagnostic codes and verify that the repair eliminates
C. Ensure that the NOx sensors are mounted securely the fault.
Result: The NOx sensors are mounted securely and not

damaged.
(continued)
268 UENR4504
(Table 203, contd)

5. Check the Address Switch Wiring for the Engine Out Less than 5 Result: The measured resistance is greater than 5 Ohms. The
NOx Sensor Ohms fault is in the address wiring for the engine out NOx sensor.
Note: The “ADDRESS” wire that is connected to the engine Replace the faulty wiring.
out NOx sensor is used by the ECM to differentiate the signal
from the engine out NOx sensor and the tailpipe out NOx Run the engine. Use the electronic service tool to clear all
sensor. logged diagnostic codes and verify that the repair eliminates
the fault.
B. Disconnect the harness connector for the engine out NOx
sensor. Proceed to Test Step 6.
C. Use a multimeter to measure the resistance between termi-

nal 5 on the harness connector and a suitable engine ground.
6. Check the Power Supply at the Suspect NOx Sensor 10 V to 14 V Result: Both voltage measurements are not within the ex-
pected range.
Install a replacement auxiliary main relay.
B. Disconnect the connectors for the NOx sensors. Run the engine. Use the electronic service tool to clear all
C. Turn the keyswitch to the ON position. the fault.
D. Use a multimeter to measure the voltage between terminal Result: One of the voltage measurements is not within the ex-
1 and terminal 2 on the harness connector for each sensor. pected range.
E. Turn the keyswitch to the OFF position. The fault is in the power supply or ground wiring for the suspect
sensor.
Run the engine. Use the electronic service tool to clear all
the fault.
Result: Both voltage measurements are within the expected

range.
7. Check the CAN Data Link CAN Data Link Result: A fault was found on the CAN data link.
A. Check the CAN data link for faults. Refer to Troubleshoot- Make any necessary repairs.
ing, “CAN Data Link - Test”. Run the engine. Use the electronic service tool to clear all
the fault.
Result: The CAN data link is OK.
Install a replacement for the suspect NOx sensor. Refer to Dis-

assembly and Assembly, “Nitrogen Oxide Sensor - Remove
and Install” for the correct procedure.
i05934515
Power Take-Off - Test
UENR4504 269
Table 204

Code
The Electronic Control Module (ECM) detects one of the following conditions:
One of the PTO switches was pressed within 2.5 seconds of the keyswitch being turned
on.
OR
PTO Governor State : Erratic, Inter- One of the PTO switches was pressed for more than 10 seconds.
976-2
mittent, or Incorrect OR
Two PTO switches were pressed at the same time for at least 0.5 seconds.
Schematic diagram for the PTO switches
270 UENR4504
PTO switches
(9) PTO mode - OFF
(10) PTO mode - resume
(31) PTO mode - raise
(32) PTO mode - lower
Table 205
B. Check the fuses.
C. Perform a 30 N (6.7 lb) pull test on each wire in the PTO switch was found. A fuse is blown.
connectors and on each wire in the ECM connector that is associ-
ated with the PTO switches. Repair the damaged wire or the damaged con-
D. Check the harness for corrosion, abrasion, and pinch points Use the electronic service tool to clear all logged
from the PTO switches to the ECM and the battery supply. diagnostic codes. Verify that the repair eliminates
the fault.
2. Check for Active Diagnostic Codes Diagnostic Trouble Result: A 976-2 diagnostic code is active.
Codes
B. Connect the electronic service tool to the diagnostic connector. Result: A 976-2 diagnostic code is recently
logged.
The logged code may be caused by operating the
D. Check the “Active Diagnostic Codes” screen. Look for an ac- PTO switches in one of the conditions that are
tive or recently logged 976-2 diagnostic code. listed in Table 204 or an intermittent fault may
exist.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” in order to identify intermittent faults.
Result: There is no active or recently logged 976-

2 diagnostic code.
If the switches are not operating correctly, an

open circuit may exist.
(continued)
UENR4504 271
(Table 205, contd)

3. Check the PTO Mode Switches on the Electronic Service Switch status Result: The status of each switch changes when
Tool the switch is operated.
A. Turn the keyswitch to the OFF position. The fault appears to be resolved. Return the en-
gine to service.
Result: One of the switches indicates “OPEN”
C. Turn the keyswitch to the ON position. even when the switch is pressed.
D. Observe the status of the PTO switch on the electronic service Proceed to Test Step 4.
tool while the PTO on/off switch is cycled.
Result: One of the switches indicates “CLOSED”
E. Use the electronic service tool in order to observe the status of even when the switch is not pressed.
the PTO mode switch while the PTO lower/raise switch is cycled.
F. Use the electronic service tool in order to observe the status of
the PTO switch while the PTO Resume switch is cycled.
4. Check the Power Supply to the Suspect Switch 10 V to 14 V Result: The measured voltage is within the ex-
pected range.
B. Disconnect the battery supply wire from the suspect switch.
Result: The measured voltage is not within the
C. Turn the keyswitch to the ON position. expected range.
D. Check the voltage between the battery supply wire to the sus- Proceed to Test Step 5.
pect switch and a suitable ground.
5. Check the Wiring Between the Suspect switch and the ECM Less than 5 Ohms Result: The measured resistance is greater than
Main Power Relay 5 Ohms.
A. Turn the keyswitch to the OFF position. The fault is in the wiring between the suspect
switch and the ECM main relay
B. Disconnect the battery supply wire from the suspect switch. Check all wiring between the suspect switch and
the ECM main relay. Refer to the Electrical Sche-
C. Disconnect the ECM main relay. matic for the application.
D. Use a multimeter to measure the resistance between the dis- Use the electronic service tool to clear all logged
connected wire and terminal 87 on the harness connector for the diagnostic codes and verify that the repair elimi-
ECM main relay. nates the fault.
Result: The measured resistance is less than 5

Ohms.
Refer to Troubleshooting, “Relay - Test (ECM

Main Relay)” in order to test the circuit for the
ECM main relay.
(continued)
272 UENR4504
(Table 205, contd)

6. Create at Short Circuit at the Switch Switch status Result: When the jumper wire is connected, the
status of the suspect PTO switch is “CLOSED” .
A. Turn the keyswitch to the OFF position. When the jumper wire is disconnected, the status
of the suspect PTO switch is “OPEN” .
B. Disconnect the connector for the suspect switch.
Replace the switch.
C. Fabricate a jumper wire and install the jumper wire between the Use the electronic service tool in order to clear all
two terminals for the switch. logged diagnostic codes and then verify that the
repair has eliminated the problem.
Result: When the jumper wire is disconnected,
E. Monitor the status screen on the electronic service tool while the status of the suspect PTO switch is
the jumper wire is being disconnected and reconnected. “CLOSED” .
Result: When the jumper wire is connected, the

status of the suspect PTO switch is “OPEN” .
7. Check the Switch Return Wire for a Short Circuit Greater than 1 k Ohm Result: At least one of the resistance measure-
ments is less than 1 k Ohm.
There is a short in the wiring between the suspect
B. Disconnect the connector for the suspect switch. Disconnect switch and the P1 ECM connector.
the P1 connector from the ECM. Check all wiring between the suspect switch and
the ECM. Refer to the Electrical Schematic for the
C. Use a suitable multimeter to measure the resistance between application.
the terminal for the suspect switch on the P1 connector and all oth-
er terminals on the P1 connector. Replace the faulty wiring.
nates the fault.
Result: All resistance measurements are greater
than 1 k Ohm.
8. Measure the Resistance of the Switch Return Wire to the Less than 5 Ohms Result: The measured resistance is greater than
ECM 5 Ohms.
A. Disconnect the P1 connector from the ECM. The fault is in the wiring between the suspect
switch and the P1 connector.
B. Thoroughly inspect the J1/P1 connectors on the ECM. Refer to Check all wiring between the suspect switch and
Troubleshooting, “Electrical Connectors - Inspect” for details. the P1 connector. Refer to the Electrical Sche-
matic for the application.
C. Measure the resistance between the appropriate pin on the P1 Replace the faulty wiring.
connector for the suspect switch and the wire to the suspect Use the electronic service tool in order to clear all
switch. Refer to Illustration 80 . logged diagnostic codes and then verify that the
repair has eliminated the fault.

Ohms.
Complete the procedure in the order in which the If the procedure did not correct the issue, Contact the
steps are listed. Dealer Solution Network (DSN).
UENR4504 273
i05939117
Relay - Test
(Start Relay)

Table 206
Diagnostic Trouble Codes for the Starting Motor Relay
677-3 Engine Starter Motor Relay : Voltage Above Normal The Electronic Control Module (ECM) detects the following conditions:
A short circuit to battery in the circuit for the starting motor relay while
no start request is detected.
The battery voltage is between 9.5 and 16 VDC.

The start relay circuit will be disabled.
677-5 Engine Starter Motor Relay : Current Below Normal The ECM detects the following conditions:
A low current condition on the circuit for the starting motor relay while
no start request is detected.

677-6 Engine Starter Motor Relay : Current Above Normal The ECM detects the following conditions:
A high current condition (short circuit) in the circuit for the starting motor
relay.
If equipped, the warning lamp will come on. The engine may be
derated.
1041-2 Start Signal Indicator : Erratic, Intermittent, or Incorrect This diagnostic code indicates that the start signal has remained active
for too long.
This condition may be caused by the keyswitch being held in the
START position for too long.
274 UENR4504
Schematic diagram for the start relay circuit
The starting motor relay supplies battery power to the

relay solenoids in the starting motor. This internal
relay provides high current battery voltage to the
starting motor.
starting motor relay
(8) Start signal
(27) Starting motor relay return
(53) Starting motor relay control

to this procedure:
When the keyswitch is turned to the START position,
a signal is sent to pin P1:8 on the engine ECM. Power
is supplied from P1:53 to the starting motor relay.
UENR4504 275
Table 207
A. Check the fuses.
B. Thoroughly inspect the P1/J1 ECM connectors and thoroughly
inspect the connector for the start relay. Refer to Troubleshooting, Result: A damaged wire or damaged connector
“Electrical Connector - Inspect” for details. was found. A fuse is blown.
D. Inspect the connections on the starting motor. Repair the damaged wire or the damaged con-
C. Perform a 30 N (6.7 lb) pull test on each of the wires that are Use the electronic service tool to clear all logged
associated with the start relay. diagnostic codes. Verify that the repair eliminates
the fault.
2. Check for Active or Recently Logged Diagnostic Codes Diagnostic Trouble Result: Diagnostic code 677-5 is active.
Codes
A. Connect the electronic service tool to the diagnostic connector. Proceed to Test Step 3.
B. If the engine will start, then start the engine. Result: Diagnostic code 677-6 or 677-3 is active.
C. Make a note of any active diagnostic codes. Proceed to Test Step 5.
Result: A 1041-2 diagnostic code is active or re-

cently logged.
If a 1041-2 diagnostic code is recently logged, this

may be caused by the keyswitch being held in the
START position for too long.
If a 1041-2 diagnostic code is active, proceed to
Test Step 9.
Result: An active diagnostic code was not

displayed.
There may be a fault with the start signal from the

keyswitch or the power circuit for the starting mo-
tor. The ECM does not monitor the status of these
conditions.
(continued)
276 UENR4504
(Table 207, contd)

3. Create a Short Circuit at the Starting Motor Relay Diagnostic codes Result: A 677-6 diagnostic code was active with
Install a replacement starting motor. Refer to Dis-
B. Disconnect the connector for the starting motor relay. assembly and Assembly, “Electric Starting Motor -
C. Fabricate a jumper wire that is 150 mm (6 inch) long. Use the electronic service tool to check for an ac-
tive 677-5 diagnostic code.
D. Use the jumper wire to connect pin 1 to pin 2 on the harness Confirm that the fault has been eliminated.
connector for the starting motor relay.
Result: A 677-5 diagnostic code is still active with
E. Turn the keyswitch to the ON position. the jumper installed.
F. Use the electronic service tool to check for an active 677-6 diag- Reconnect the starting motor relay and proceed
nostic code. to Test Step 4.
H. Remove the jumper.
4. Check the Wiring Between the Start Relay and the ECM for Less than 5 Ohms Result: Each resistance measurement is less
an Open Circuit than 5 Ohms.
A. Turn the keyswitch to the OFF position. Contact the Dealer Solution Network (DSN).
B. Disconnect the starting motor relay connector. Disconnect the Result: At least one of the resistance measure-
P1 connector. ments is greater than 5 Ohms.
C. Use a suitable multimeter to measure the resistance between There is open circuit or high resistance in the wir-
the following points: ing between the start relay connector and the P1
connector.
·P1:53 to terminal 1 on the harness connector for the start relay Check all wiring between the start relay connector
·P1:27 to terminal 2 on the harness connector for the start relay and the ECM. Refer to the Electrical Schematic
for the application.
nates the fault.
5. Create an Open Circuit at the Relay Diagnostic codes Result: A 677-5 diagnostic code became active
with the starting motor relay disconnected.
Install a replacement starting motor. Refer to Dis-
B. Disconnect the starting motor relay connector. assembly and Assembly, “Electric Starting Motor -
C. Turn the keyswitch to the ON position. Use the electronic service tool to check for an ac-
tive 677-5 diagnostic code.
D. Use the electronic service tool to check for an active 677-5 di- Confirm that the fault has been eliminated.
agnostic code.
Result: A 677-6 diagnostic code is still active with
E. Turn the keyswitch to the OFF position. the starting motor relay disconnected.
F. Reconnect the starting motor relay connector. Proceed to Test Step 6.
(continued)
UENR4504 277
(Table 207, contd)

6. Check the Wiring Between the Start Relay and the ECM for Greater than 1 k Ohm Result: Each resistance measurement is greater
a Short Circuit than 1 k Ohm.
B. Disconnect the start relay connector. Disconnect the P1 con- Result: At least one of the resistance measure-
nector from the ECM. ments is less than 1 k Ohm.
C. Use a multimeter to measure the resistance between the follow- There is a short in the wiring between the start re-
ing points: lay connector and the P1 connector.
Check all wiring between the start relay connector
·P1:53 and all other terminals on the P1 connector and the P1 connector. Refer to the Electrical
·P1:27 and all other terminals on the P1 connector Schematic for the application.
nates the fault.
7. Check the Start Signal Wire 10 V to 14 V Result: The measured voltage is less than 10 V.
A. Turn the keyswitch to the OFF position. The fault is in the start signal wiring.
Check all of the start signal wiring between the
B. Disconnect the P1 connector from the engine ECM. ignition keyswitch and the ECM. Refer to the Elec-
trical Schematic for the application.
C. Use a suitable voltmeter to measure between P1:8 and ground. Replace the faulty wiring.
D. With the keyswitch held in the START position, note the voltage diagnostic codes and verify that the repair elimi-
on the voltmeter. nates the fault.
E. Turn the keyswitch to the OFF position. Result: The measured voltage is within the ex-
pected range.
F. Reconnect the P1 connector to the engine ECM.
8. Check the Wiring Between the Batteries and the Starting 10 V to 14 V Result: All voltage readings are OK
Motor
Replace the starting motor. Refer to Disassembly
A. Use a voltmeter to check the voltage between the battery+ ter- and Assembly, “Electric Starting Motor - Remove
minal on the starting motor and a suitable ground on the engine. and Install”.
The voltmeter must read battery voltage. If the reading is less than
battery voltage, there is a fault in the wiring between the battery Result: At least one of the measured voltages is
positive terminal and the starting motor. not within the expected range.
B. Use a voltmeter to check the voltage between the battery+ ter- The fault is in the wiring between the batteries
minal and the ground terminal on the starting motor. The voltmeter and the starting motor.
must read battery voltage. If the reading is less than battery volt- Check all wiring between the batteries and the
age, there is a fault in the wiring between the battery negative ter- starting motor. Refer to the Electrical Schematic
minal and the starting motor. for the application.
nates the fault.
(continued)
278 UENR4504
(Table 207, contd)

9. Check the Start Signal Voltage at the ECM Connector 10 V to 14 V Result: The voltage is within the expected range.
B. Disconnect the P1 connector from the ECM. Result: There is no voltage present.
C. Turn the keyswitch to the ON position. Do not attempt to start Contact the Dealer Solution Network (DSN).
the engine.
D. Use a suitable multimeter to measure the voltage between P1:8

and a suitable ground.
10. Check the Start Signal Voltage at the Keyswitch 10 V to 14 V Result: The measured voltage is within the ex-
Connector pected range.
A. Turn the keyswitch to the OFF position. Install a replacement ignition keyswitch.
B. Disconnect the electrical connector for the ignition keyswitch. diagnostic codes and verify that the repair elimi-
nates the fault.
C. Disconnect the wire from the start signal “S” terminal on the
connector for the ignition keyswitch. Result: The measured voltage is not within the
expected range.
D. Reconnect the electrical connector for the ignition keyswitch.
The fault is in the start signal wiring between the
E. Turn the keyswitch to the ON position. Do not attempt to start ignition keyswitch and the ECM.
the engine. Check all wiring between the ignition keyswitch
and the ECM. Refer to the Electrical Schematic
F. Use a suitable multimeter to measure the voltage between the for the application.
start signal “S” terminal on the connector for the ignition key-
switch and a suitable ground. Replace the faulty wiring.
nates the fault.

steps are listed.
i05934598
Relay - Test
(ECM Main Relay)
UENR4504 279
Table 208

Code
The Electronic Control Module (ECM) detects that the battery supply voltage is still present
0.5 seconds after the shut-off request from the ECM.
ECM Main Relay : Not Responding
1485-7
The ECM is receiving battery voltage after the keyswitch has been turned OFF, which will
drain battery power.
The ECM requires battery voltage for up to 60 seconds after the keyswitch has been turned
OFF.
A fault is caused when the ECM has lost battery voltage before this period has elapsed.
The fault is detected the next time the keyswitch is turned ON. The diagnostic code be-
comes active when the fault is detected for three consecutive starts.
1485-14 ECM Main relay : Special Instruction
This condition is most likely caused by shutting the engine down using the battery discon-
nect switch instead of the keyswitch for three consecutive shutdowns or using the battery
disconnect switch immediately after the keyswitch has been turned OFF.
2840-14 ECU Instance : Special Instruction The ECM was unable to write data to the internal memory.
This condition is most likely caused by removing battery power from the ECM while the
ECM was attempting to write data to the internal memory.
280 UENR4504
Schematic diagram for the ECM main relay
ignition keyswitch and battery supply circuit
(1) Battery+
(2) Battery ground
(3) Battery+
(4) Battery ground
(5) Battery+
(6) Battery ground
(28) ECM main relay
(54) Ignition key switch
UENR4504 281
Table 209
A. Check the fuses.
inspect the connector for the ECM main relay. Refer to Trouble- Result: A damaged wire or damaged connector
shooting, “Electrical Connectors - Inspect” for details. was found. A fuse is blown.
C. Perform a 30 N (6.7 lb) pull test on each of the wires that are Repair the damaged wire or the damaged con-
associated with the main relay. nector. Replace any blown fuses.
the fault.
2. Check for Diagnostic Codes Diagnostic Trouble Result: A 1485-7 diagnostic code is active or re-
Codes cently logged.
Result: A 1485-14 or 2840-14 diagnostic code is
C. Turn the keyswitch to the ON position. active or recently logged.
D. Monitor the electronic service tool for active diagnostic codes Ensure that the correct procedure is used to shut
and/or logged diagnostic codes. down the engine. Refer to Operation and Mainte-
nance Manual, “Stopping the Engine”.
If the engine is being shut down correctly, an inter-
mittent fault may be causing the ECM to lose bat-
tery power. Refer to Troubleshooting, “Electrical
Power Supply - Test” and refer to Troubleshoot-
ing, “Electrical Connectors - Inspect”.
(continued)
282 UENR4504
(Table 209, contd)

3. Check the ECM Main Relay Open circuit Result: The resistance measurement indicates
“Open Circuit”
B. Disconnect the ECM main relay.
Result: The resistance measurement indicates
C. Measure the resistance between Test Point C (terminal 30) and continuity between Test Point C and Test Point D
Test Point D (terminal 87) on the relay. on the relay.
Replace the ECM main relay.

nates the fault.
4. Check the Wiring Between the Relay and the ECM 0V Result: The voltage measurement is 0 VDC.
B. Disconnect the ECM main relay. Disconnect the P1 connector. Result: The voltage measurement indicates bat-
tery voltage.
C. Measure the voltage between Test Point A (terminal 86) and
Test Point B (terminal 85) on the harness connector for the ECM The wiring between Test Point B on the harness
main relay. connector for the relay and P1:28 is shorted to
ground.
Check all wiring between the ECM main relay and
the P1 connector. Refer to the Electrical Sche-
matic for the application.
nates the fault.

steps are listed.
If the procedure did not correct the issue, contact the
i05934745
Relay - Test
(SCR Relay)
UENR4504 283
Table 210

Code
The Electronic Control Module (ECM) detects an open circuit condition for the Selective
Catalytic Reduction (SCR) relay control circuit for at least 2 seconds.
The ECM is not attempting to activate the relay.
Aftertreatment #1 DEF Control Mod-
5965-5 ule Relay Control : Current Below
Normal The ECM detects a short circuit to battery condition for the SCR relay control circuit for at
least 0.2 seconds.
The ECM is attempting to activate the relay.
The ECM detects a high current condition for the SCR relay control circuit for a least 0.05
seconds.
The ECM is attempting to activate the relay.
5965-6 ule Relay Control : Current Above
Normal The ECM detects a short circuit to ground condition for the SCR relay control circuit for at
least 0.2 seconds.
The ECM is not attempting to activate the relay.
The ECM detects that the components connected to the SCR relay are not receiving
Aftertreatment #1 DEF Control Mod- power.
5965-7 ule Relay Control : Not Responding The SCR relay has been activated.
Properly The battery voltage is at least 10 V.
The ECM detects that the components connected to the SCR relay are still receiving power
after the SCR relay has been deactivated.
5965-14 ule Relay Control : Special
Instruction
Note: Some diagnostic codes can only be detected

when the SCR relay is not active. These codes will be
detected after the keyswitch has been turned to the
OFF position and before the ECM main relay
removes electrical power from the ECM. These
diagnostic codes will be logged the next time that the
keyswitch is turned to the ON position.
Schematic diagram for the SCR relay circuit
284 UENR4504
SCR relay
(20) SCR relay control
UENR4504 285
Table 211
A. Check the fuses.
inspect the connector for the SCR relay. Refer to Troubleshooting, Result: A damaged wire or damaged connector
“Electrical Connectors - Inspect” for details. was found. A fuse is blown.
C. Perform a 30 N (6.7 lb) pull test on each of the wires that are Repair the damaged wire or the damaged con-
associated with the SCR relay. nector. Replace any blown fuses.
the fault.
2. Check for Active or Recently Logged Diagnostic Codes Diagnostic Trouble Result: A 5965-5 diagnostic code is active (short
Codes circuit to battery).
The fault is in the wiring between the SCR relay
B. Connect the electronic service tool to the diagnostic connector. and the ECM.
Replace the faulty wiring. Use the electronic serv-
C. Turn the keyswitch to the ON position. ice tool to clear all logged diagnostic codes and
verify that the repair eliminates the fault.
D. Monitor the electronic service tool for active diagnostic codes
and/or logged diagnostic codes. Result: A 5965-5 diagnostic code is recently
logged (open circuit).
Note: Some diagnostic codes can only be detected when the SCR
relay is not active. These codes will be detected after the key- Proceed to Test Step 3.
switch has been turned to the OFF position and before the ECM
main relay removes electrical power from the ECM. These diag- Result: A 5965-6 diagnostic code is active (high
nostic codes will be logged the next time that the keyswitch is current).
turned to the ON position.
Check that the correct specification of relay is in-
stalled. If necessary, install a replacement relay.
Result: A 5965-6 diagnostic code is recently

logged (short circuit to ground).
Result: A 5965-14 diagnostic code is recently

logged.
(continued)
286 UENR4504
(Table 211, contd)

3. Check the Power Supply from the ECM Main Relay 10 V to 14 V Result: The measured voltage is not within the
expected range.
B. Disconnect the SCR relay.
Result: The measured voltage is within the ex-
C. Turn the keyswitch to the ON position. pected range.
D. Use a multimeter to measure the voltage between terminal 85 Proceed to Test Step 5.
on the harness connector for the SCR relay and a suitable ground.
4. Check the Wiring Between the Relay and the ECM Less than 5 Ohms Result: The measured resistance is greater than
5 Ohms.
The fault is in the wiring between the SCR relay
B. Disconnect the SCR relay. Disconnect the P2 connector. and the P2 ECM connector.
C. Use a multimeter to measure the voltage between terminal 86 Use the electronic service tool to clear all logged
on the harness connector for the relay and P2:20. diagnostic codes and verify that the repair elimi-
nates the fault.

Ohms.
5. Check the Wiring Between the SCR Relay and the ECM Less than 5 Ohms Result: The measured resistance is greater than
Main Relay 5 Ohms.
A. Turn the keyswitch to the OFF position. Check the fuse.

If the fuse is OK, the fault is in the wiring between
B. Disconnect the SCR relay and the ECM main relay. the SCR relay and the ECM main relay.
C. Use a multimeter to measure the resistance between terminal Use the electronic service tool to clear all logged
85 on the harness connector for the SCR main relay and terminal diagnostic codes and verify that the repair elimi-
87 on the harness connector for the ECM main relay. nates the fault.

Ohms.
Test the circuit for the ECM main relay. Refer to
Troubleshooting, “Relay - Test (ECM Main
Relay)”.
(continued)
UENR4504 287
(Table 211, contd)

6. Check the SCR Relay Wiring for a Short to Ground Greater than 1 k Ohm Result: At least one of the resistance measure-
ments is less than 1 k Ohm.
The fault is in the wiring for the SCR relay.
B. Disconnect the SCR relay. Disconnect the P2 ECM connector. Replace the faulty wiring.
C. Use a multimeter to measure the resistance between the follow- diagnostic codes and verify that the repair elimi-
ing points: nates the fault.
· Terminal 85 on the harness connector for the SCR relay and a Result: Both resistance measurements are great-
suitable ground er than 1 k Ohm.
· Terminal 86 on the harness connector for the SCR relay and a
suitable ground Install a replacement SCR relay.
nates the fault.
7. Check the Battery Supply to the SCR Relay 10 V to 14 V Result: The measured voltage is not within the
expected range.
The fault is in the battery supply wiring to the SCR
B. Disconnect the SCR Relay. relay.
C. Use a multimeter to measure the voltage between terminal 30 Use the electronic service tool to clear all logged
on the harness connector for the SCR relay and a suitable ground. diagnostic codes and verify that the repair elimi-
nates the fault.
Result: The measured voltage is within the ex-

pected range.
(continued)
288 UENR4504
(Table 211, contd)

8. Check the Wiring Between the SCR Relay and the After- Less than 5 Ohms Result: At least one of the resistance measure-
treatment Components ments is greater than 5 Ohms.
A. Turn the keyswitch to the OFF position. Check the fuses.

If the fuses are OK, the fault is in the wiring be-
B. Disconnect the SCR relay. Disconnect the connector for the tween the SCR relay and the aftertreatment
DEF pump module. Disconnect the connector for the coolant components.
diverter valve. Replace the faulty wiring.
C. Use a multimeter to measure the resistance between terminal diagnostic codes and verify that the repair elimi-
87 on the harness connector for the SCR relay and the following nates the fault.
points:
Result: All the resistance measurements are less
· Terminal 9 on the harness connector for the DEF pump module than 5 Ohms.
· Terminal 5 on the harness connector for the DEF pump module
· Terminal 1 on the harness connector for the coolant diverter Install a replacement SCR relay.
valve. Use the electronic service tool to clear all logged
nates the fault.
9. Check the Voltage to the Aftertreatment Components With 10 V to 14 V Result: The voltage is within the expected range.
the SCR Relay Disconnected
There is a short to battery in the wiring between
A. Turn the keyswitch to the OFF position. the SCR relay and the aftertreatment
components.
B. Disconnect the SCR relay. Disconnect the connector for the Replace the faulty wiring.
DEF Pump Module. Disconnect the connector for the coolant Use the electronic service tool to clear all logged
diverter valve. diagnostic codes and verify that the repair elimi-
nates the fault.
Result: There is no voltage present.
D. Use a multimeter to measure the voltage between the following
points and a suitable ground: Install a replacement SCR relay.
· Terminal 9 on the harness connector for the DEF pump module diagnostic codes and verify that the repair elimi-
· Terminal 5 on the harness connector for the DEF pump module nates the fault.
· Terminal 1 on the harness connector for the coolant diverter
valve.

steps are listed.
i05940209
Sensor (Data Link Type) - Test

(Ammonia Sensor)
UENR4504 289
Table 212
Diagnostic Trouble Codes for the Ammonia Sensor

4377-2 Aftertreatment 1 Outlet NH3 : Er- The Electronic Control Module (ECM) detects an open or short circuit error message for one
ratic, Intermittent, or Incorrect of the ammonia sensor measuring cell lines for at least 12 seconds.
4377-4 Aftertreatment 1 Outlet NH3 : Volt- The ECM detects an open circuit error message for the signal ground line of the ammonia
age Below Normal sensor for at least 2 seconds.
4377-7 Aftertreatment 1 Outlet NH3 : Not The ECM detects an open or short circuit error message for the temperature cell input line or
Responding Properly the trim resistor line input of the ammonia sensor for at least 2 seconds.
4377-12 Aftertreatment 1 Outlet NH3 : The ECM detects an invalid signal from the ammonia sensor for at least 2 seconds.
Failure The warning lamp will flash. The engine will be derated.
4377-19 Aftertreatment 1 Outlet NH3 : Data The ECM detects a loss of signal from the ammonia sensor for at least 0.5 seconds.
Error The warning lamp will come on.
4377-20 Aftertreatment 1 Outlet NH3 : Data The ECM detects that the sensor signal has drifted outside of the acceptable values for at
Drifted High least 20 seconds.
4383-5 Aftertreatment 1 Outlet NH3 Gas The ECM detects a low current condition on the ammonia sensor heater circuit for at least 2
Sensor Heater Control : Current seconds.
Below Normal The warning lamp will flash. The engine will be derated.
4383-6 Aftertreatment 1 Outlet NH3 Gas The ECM detects a high current condition on the ammonia sensor heater circuit for at least 2
Sensor Heater Control : Current seconds.
Above Normal The warning lamp will flash. The engine will be derated.
4383-7 Aftertreatment 1 Outlet NH3 Gas The ECM detects an error message from the ammonia sensor for the sensor heater circuit
Sensor Heater Control : Not Re- at least 15 seconds.
sponding Properly The warning lamp will flash. The engine will be derated.
Schematic diagram for the ammonia sensor
290 UENR4504
ammonia sensor.
(23) J1939 CAN 2 +
(45) J1939 CAN 2 -
Table 213
A. Check the fuses.
B. Thoroughly inspect the connectors for the ammonia sensor. any blown fuses.
Refer to Troubleshooting, “Electrical Connector - Inspect” for Use the electronic service tool to clear all logged diagnostic co-
C. Thoroughly inspect the P1/J1 ECM connector . Refer to Result: All connectors, pins, and sockets are correctly con-
Troubleshooting, “Electrical Connector - Inspect” for details. nected and/or inserted and the harness is free of corrosion, of
abrasion or of pinch points. The fuses are OK.
D. Perform a 30 N (6.7 lb) pull test on each of the wires that
are associated with the ammonia sensor. Proceed to Test Step 2.
2. Check for Diagnostic Codes Diagnostic Result: A diagnostic code other than those listed in Table 212
codes is active or recently logged.
Troubleshoot the other diagnostic codes before returning to this
B. Connect the electronic service tool to the diagnostic procedure. Refer to Troubleshooting, “Diagnostic Trouble
connector. Codes”.
C. Turn the keyswitch to the ON position. Result: One of the diagnostic listed in Table 212 is active or re-
cently logged.
des and/or logged diagnostic codes. Proceed to Test Step 3.
Result: None of the diagnostic codes listed in Table 212 are

active or recently logged.

cal Connector - Inspect” in order to identify intermittent faults.
(continued)
UENR4504 291
(Table 213, contd)

3. Inspect the Exhaust System for Leaks Exhaust leaks Result: There is a leak in the exhaust system.
A. Thoroughly inspect the exhaust system for leaks. Refer to Make any necessary repairs.
Systems Operation, Testing and Adjusting, “Air Inlet and Ex- Run the engine. Use the electronic service tool in order to clear
haust System - Inspect”. all logged diagnostic codes and then verify that the repair elimi-
nates the fault.
4. Inspect the Ammonia Sensor Ammonia Result: Fault found with the ammonia sensor.
sensor
A. Inspect the ammonia sensor for damage. Make any necessary repairs. If necessary, replace a damaged
ammonia sensor. Refer to Disassembly and Assembly for the
B. Check that the ammonia sensor is mounted in the correct correct procedure.
position. Run the engine. Use the electronic service tool to clear all
C. Ensure that the ammonia sensor is mounted securely the fault.
Result: The ammonia sensor is mounted securely and not

damaged.
5. Check the Power Supply at the Ammonia Sensor 10 V to 14 V Result: The measured voltage is not within the expected
range.
B. Disconnect the connector for the ammonia sensor.
D. Use a multimeter to measure the voltage between terminal
1 and terminal 4 on the harness connector for the ammonia
sensor.
6. Check the Power Supply and Ground Wiring for the Am- Less than 5 Result: At least one of the resistance measurements is greater
monia Sensor Ohms than 5 Ohms.
A. Turn the keyswitch to the OFF position. Check the fuse.

If the fuse is OK, the fault is in the power supply or ground wir-
B. Disconnect the connector for the ammonia sensor. Discon- ing for the ammonia sensor.
nect the auxiliary main relay. Replace the faulty wiring.
C. Use a multimeter to measure the resistance between the des and verify that the repair eliminates the fault.
following points:
Result: Both resistance measurements are less than 5 Ohms.
· Terminal 1 on the harness connector for the ammonia sensor
and terminal 87 on the harness connector for the auxiliary Install a replacement auxiliary main relay.
main relay. Use the electronic service tool to clear all logged diagnostic co-
· Terminal 4 on the harness connector for the ammonia sensor des and verify that the repair eliminates the fault.
(continued)
292 UENR4504
(Table 213, contd)

7. Check the CAN Data Link CAN Data Link Result: A fault was found on the CAN data link.
A. Check the CAN data link for faults. Refer to Troubleshoot- Make any necessary repairs.
ing, “CAN Data Link - Test”. Run the engine. Use the electronic service tool to clear all
the fault.
Result: The CAN data link is OK.
Install a replacement ammonia sensor. Refer to Disassembly

and Assembly for the correct procedure.
i05941751
Sensor Supply - Test

Table 214
Diagnostic trouble Codes for the Sensor Supply Circuits
J1939
Description Notes
Code
3509-2 Sensor Supply Voltage 1 : Erratic, Intermittent, The Electronic Control Module (ECM) detects a fault in the 5 VDC sensor supply
or Incorrect circuit supplied on the following pins:
J2:8
J2:9
J2:10
J2:11
J2:13
If equipped, the warning lamp will come on. The engine will be derated.
or Incorrect circuit supplied on the following pins:
J1:16
If equipped, the warning lamp will come on. The engine will be derated.
or Incorrect circuit supplied on the following pin:
J1:17
J1:18
The following background information is related • The position sensor for the intake throttle valve
to this procedure:
• The position sensor for the Exhaust Gas
The ECM supplies regulated +5 VDC to the following Recirculation (EGR) valve
sensors on the J2 connector (a 3509-2 diagnostic
code applies to the 5 VDC supply for these sensors) : • The intake manifold air pressure/temperaure
sensor
• The fuel rail pressure sensor

• The secondary (camshaft) speed/timing sensor
UENR4504 293
The ECM supplies regulated +5 VDC to analog

throttle position sensor 1 on the J1 connector. A
3510-2 diagnostic code applies to the 5 VDC supply
for this sensor.
The ECM supplies regulated +5 VDC to the following
sensors on the J1connector (a 3510-2 diagnostic
code applies to the 5 VDC supply for these sensors) :
• The exhaust gas pressure sensor
• Analog throttle position sensor 2
Schematic diagram of the 5 VDC supply circuit supplied by the J2 connector.
Typical example of the 5 VDC supply circuit supplied by the J1 connector. A 3510-2 diagnostic code applies to the 5
VDC supply in this illustration.
294 UENR4504
Typical example of the 5 VDC supply circuit supplied by the J1 connector. A 3511-2 diagnostic code applies to the 5
VDC supply in this illustration.

interface connector for the 5 VDC supply for the 5 VDC supply.
(5) Fuel rail pressure sensor ground (8) Intake throttle valve position sensor 5 VDC supply
(7) Fuel rail pressure sensor 5 VDC supply (9) EGR valve position sensor 5 VDC supply
(8) Secondary (camshaft) speed/timing sensor ground (10) Intake manifold air pressure sensor 5 VDC supply
(12) Secondary (camshaft) speed/timing sensor 5 VDC supply (11) Fuel rail pressure sensor 5 VDC supply
(17) Intake manifold air pressure sensor 5 VDC supply (13) Secondary (camshaft) speed/timing sensor 5 VDC supply
(19) Intake manifold air pressure sensor ground (24) EGR valve position sensor ground
(21) Exhaust gas pressure sensor 5 VDC supply (25) Intake manifold air pressure sensor
(22) Exhaust gas pressure sensor ground (26) Fuel rail pressure sensor ground
(33) Exhaust Gas Recirculation (EGR) valve position sensor 5 VDC (28) Secondary (camshaft) speed/timing sensor ground
supply (37) Intake throttle valve position sensor ground
(35) EGR valve position sensor ground
(41) Intake throttle valve position sensor 5 VDC supply
(43) Intake throttle valve position sensor ground
UENR4504 295
for the 5 V supply
(16) Analog throttle position sensor (1) 5 V supply
(17) Analog throttle position sensor (2) 5 V supply
(18) Exhaust gas pressure sensor 5 V supply
(37) Exhaust gas pressure sensor ground
(38) Analog throttle position sensor (1) ground
(39) Analog throttle position sensor (2) ground
296 UENR4504
Table 215
A. Check the fuses.
B. Turn the keyswitch to the OFF position. any blown fuses.
C. Check the connectors for the components on the 5 VDC des. Verify that the repair eliminates the fault.
supply circuit and the harness for the following faults:
Result: All connectors, pins, and sockets are correctly con-
· Damage nected and/or inserted and the harness is free of corrosion, of
· Abrasion abrasion or of pinch points.
· Corrosion
· Incorrect attachment Proceed to Test Step 2.
Refer to Troubleshooting, “Electrical Connectors - Inspect”
D. Thoroughly inspect the P2/J2 connectors for corrosion and/

or damaged seals.

harness that are associated with the 5 VDC supply. Check the
wire connectors for all the sensors on the 5 VDC supply
circuit.
F. Perform a 30 N (6.7 lb) pull test on each of the wires in the

ECM connector that are associated with glow plug circuit.
G. Check the harness for abrasions and for pinch points from
each of the sensors on the 5 VDC supply back to the ECM.
2. Check for Active Diagnostic Codes Diagnostic Result: Diagnostic code 3509-2 or 3511-2 is active.
codes
A. Connect the electronic service tool to the diagnostic Proceed to Test Step 3.
connector.
Result: Diagnostic code 3510-2 is active.
C. Use the electronic service tool in order to monitor the diag- Result: No 5 VDC sensor supply circuit diagnostic codes are
nostic codes. Check and record any active diagnostic codes. active.
Note: Wait at least 15 seconds in order for the diagnostic co-
des to become active. If a 5 VDC sensor supply circuit diagnostic code is recently
logged, the fault may be intermittent.
Refer to Troubleshooting, “Electrical Connectors - Inspect” in
(continued)
UENR4504 297
(Table 215, contd)

3. Disconnect the 62-Pin Engine Interface Connector Diagnostic Result: The 3509-2 or 3511-2 diagnostic code is cleared when
codes the 62-pin connector is disconnected.
The fault is in the engine harness or the engine sensors.
B. Disconnect the 62-pin engine interface connector. Reconnect the 62-pin connector and proceed to Test Step 4.
C. Turn the keyswitch to the ON position. Result: A 3509-2 or 3511-2 diagnostic code is still active with
the 62-pin connector disconnected.
D. Use the electronic service tool to check for an active 3509-
2 or 3511-2 diagnostic code. The fault is in the wiring between the 62-pin connector and the
Note: Diagnostic codes for all of the engine sensors and elec- ECM.
trical components will become active. Ignore all other diagnos- Replace the faulty wiring.
tic codes and look for an active 3509-2 or 3511-2 code only. Use the electronic service tool to clear all logged diagnostic co-
4. Disconnect the Sensors One at a Time Diagnostic code Result: The 3509-2, 3510-2, or 3511-2 diagnostic code be-
comes inactive when one of the sensors is disconnected.
The fault is in the sensor that caused the 3509-2, 3510-2, or
B. Disconnect one of the sensors on the suspect 5 VDC sup- 3511-2 diagnostic code to become inactive.
ply. Refer to Illustration 90 , Illustration91 , and Illustration 92 . Replace the faulty sensor.
Reconnect all of the engine sensors. Use the electronic service
C. Turn the keyswitch to the ON position. tool to clear all logged diagnostic codes and verify that the re-
pair eliminates the fault.
D. Use the electronic service tool in order to monitor the active
diagnostic codes. Result: The 3509-2, 3510-2, or 3511-2 diagnostic code is still
active with all of the sensors disconnected.
E. Use the electronic service tool to check for an active 3509-
2, 3510-2, or 3511-2 diagnostic code. The fault is in the engine wiring harness.
Note: Diagnostic code 3509-2, 3510-2, or 3511-2 will become Replace the engine wiring harness.
inactive when the component that caused the code is Use the electronic service tool to clear all logged diagnostic co-
disconnected. des and verify that the repair eliminates the fault.
F. Disconnect all other sensors on the 5 VDC supply one at a

time while monitoring the “Active Diagnostic Code” screen on
the electronic service tool.
Note: The keyswitch must be cycled every time a sensor is
disconnected in order to reset the diagnostic codes.
Note: Other diagnostic codes will become active with the sen-
sors disconnected. Only look for a 3509-2, 3510-2, or 3511-2
diagnostic code.
If the procedure did not correct the fault, contact the Dealer Solution Network (DSN)
i05942949
Sensor Signal (Analog, Active)

- Test
(Exhaust Gas Pressure Sensor)
298 UENR4504
Table 216
Diagnostic Trouble Codes for the Exhaust Gas Pressure Sensor

Code
1209-3 Engine Exhaust Gas The ECM detects the following conditions:
Pressure : Voltage Above
Normal The signal voltage from the exhaust gas pressure sensor is greater than 4.74 VDC for at least 1.8
seconds.
The ECM will use the default value for exhaust gas pressure while this code is active. The default value
is 50 kPa (7.25 psi).
1209-4 Engine Exhaust Gas The ECM detects the following conditions:
Pressure : Voltage Below
Normal The signal voltage from the exhaust gas pressure sensor is less than 0.4 VDC for at least 1.8 seconds.
The ECM will use the default value for exhaust gas pressure while this code is active. The default value
is 50 kPa (7.25 psi).
The following conditions must exist before any of the

above codes will become active:
• There are no active 3509 codes.

to this procedure:
The 5 V sensor supply provides power to all 5 V
sensors. The ECM supplies 5.0 ± 0.1 V to each of the
pressure sensor connectors. The sensor supply is
output short circuit protected. A short circuit to the
battery will not damage the circuit inside the ECM.
Schematic diagram for the exhaust gas pressure sensor
UENR4504 299
View of the pin locations on the 62-pin connector for
the exhaust gas pressure sensor
(23) Exhaust gas pressure sensor signal
exhaust gas pressure sensor
(57) Exhaust gas pressure sensor signal
300 UENR4504
Table 217
or connector
A. Thoroughly inspect the terminal connections on the P2/J2 Repair the damaged wire or the damaged connector.
ECM connector. Refer to Troubleshooting, “Electrical Connec- Use the electronic service tool to clear all logged diagnostic co-
tors - Inspect”. des. Verify that the repair eliminates the fault.
B. Thoroughly inspect the connector for the exhaust gas pres- Result: All connectors, pins, and sockets are correctly con-
sure sensor. Refer to Troubleshooting, “Electrical Connectors nected and/or inserted and the harness is free of corrosion, of
- Inspect”. abrasion or of pinch points.
C. Perform a 30 N (6.7 lb) pull test on each of the wires in the Proceed to Test Step 2.
ECM connector and the sensor connectors that are associ-
ated with the exhaust gas pressure sensor.
D. Check the harness for abrasions and for pinch points from
the exhaust gas pressure sensor back to the ECM.
2. Check For Active Diagnostic Codes Diagnostic Result: None of the preceding diagnostic codes are active.
codes
A. Turn the keyswitch to the ON position. Wait at least 10 sec- If the codes in Table 216 are logged, an intermittent condition
onds for activation of the diagnostic codes. may be causing the logged codes. Refer to Troubleshooting,
“Electrical Connectors - Inspect”.
B. Verify if any of the diagnostic codes that are listed in Table
216 are active. Result: A 1209-3 or a 1209-4 diagnostic code is active.
3. Check the Supply Voltage at the Sensor Connector 4.9 V to 5.1 V Result: The voltage measurement is not within the expected
range.
B. Disconnect the connector for the exhaust gas pressure
sensor. Result: The voltage measurement is within the expected
range.
C. Turn the keyswitch to the ON position. Do not start the
D. Measure the voltage between terminal 1 and terminal 2 on

the harness connector for the exhaust gas pressure sensor.
The voltage measurement should be 5.0 ± 0.1 VDC.
F. Reconnect the sensor.
(continued)
UENR4504 301
(Table 217, contd)

4. Check the Supply Voltage at the 62-Pin Connector 4.9 V to 5.1 V Result: The voltage measurement is 5.0 ± 0.1 V.
A. Turn the keyswitch to the OFF position. The fault is in the 5 V supply wire or the ground wire between
the 62-pin engine interface connector and the sensor.
Use the electronic service tool to verify that the repair elimi-
C. Turn the keyswitch to the ON position. Do not attempt to nates the fault.
start the engine.
Result: The voltage measurement is not 5.0 ± 0.1 V.
D. Measure the voltage between terminal 21 and terminal 22
on the 62-pin connector on the harness between the engine The fault is in the 5 V supply wire or the ground wire between
and the ECM. The voltage measurement should be 5.0 ± 0.1 the 62-pin engine interface connector and the ECM.
V. Replace the faulty wiring.
E. Turn the keyswitch to the OFF position. nates the fault.
F. Reconnect the 62-pin connector.
5. Verify the Type of Active Diagnostic Code Diagnostic Result: A 1209-3 diagnostic code is active.
codes
A. Turn the keyswitch to the ON position. Wait at least 10 sec- Proceed to Test Step 6.
codes. Record all active diagnostic codes. Proceed to Test Step 8.
C. Determine if the fault is related to an open circuit diagnostic Result: Neither of the preceding diagnostic codes are active.
code or a short circuit diagnostic code.
An intermittent fault may exist.
6. Create An Open Circuit at the Sensor Connector Diagnostic Result: A 1209-4 diagnostic code became active after discon-
codes necting the sensor.
Temporarily connect a new exhaust gas pressure sensor to the
B. Disconnect the connector for the exhaust gas pressure harness, but do not install the new sensor in the engine. Use
sensor. the electronic service tool in order to verify that the repair elimi-
nates the fault and then permanently install the new sensor.
C. Turn the keyswitch to the ON position. Wait for at least 10 Use the electronic service tool in order to clear all logged diag-
seconds for activation of the diagnostic codes. nostic codes.
D. Use the electronic service tool to check the “Active Diag-
nostic Code” screen. Check for an active 1209-4 diagnostic Result: The 1209-3 diagnostic code is still active with the ex-
code. haust gas pressure sensor disconnected.
(continued)
302 UENR4504
(Table 217, contd)

7. Create an Open Circuit at the 62-Pin Connector Diagnostic Result: A 1209-3 diagnostic code became active after the 62-
Codes pin connector was disconnected.
The fault is in the wiring between the suspect sensor and the
B. Disconnect the 62-pin connector. 62-pin ECM connector.
tive with the 62-pin connector disconnected. Ignore all other Result: The 1209-4 diagnostic code is still active with the 62-
diagnostic codes and only look for a 1209 diagnostic code. pin connector disconnected.
D. Access the “Active Diagnostic Codes” screen on the elec- The fault is in the wiring between the 62-pin connector and the
tronic service tool and check for an active 1209-3 diagnostic ECM.
code for the suspect sensor. Replace the faulty wiring.
E. Turn the keyswitch to the OFF position. des and verify that the repair eliminates the fault.
8. Create a Short at the Sensor Connector Diagnostic Result: A 1209-3 diagnostic code was active with the jumper
codes installed.
Temporarily connect a new exhaust gas pressure sensor to the
B. Disconnect the connector for the exhaust gas pressure harness, but do not install the new sensor in the engine. Use
sensor. the electronic service tool in order to verify that the repair elimi-
nates the fault and then permanently install the new sensor.
the jumper wire between terminal 1 and terminal 3 on the har- des and verify that the repair eliminates the fault.
ness connector for the exhaust gas pressure sensor.
Result: A 1209-4 diagnostic code is still active with the jumper
D. Turn the keyswitch to the ON position. Wait at least 10 sec- installed.
3 diagnostic code.
F. Turn the keyswitch to the OFF position. Remove the jumper

wire.
9. Create a Short at the 62-Pin Connector Diagnostic Result: A 1209-4 diagnostic code was active with the jumper
codes installed.
B. Disconnect the 62-pin connector. 62-pin connector.
the jumper wire between terminal 21 and terminal 23 on the des and verify that the repair eliminates the fault.
62-pin connector on the harness between the engine and the
ECM. Result: A 1209-3 diagnostic code is still active with the jumper
installed.
onds for activation of the diagnostic codes. The fault is in the wiring between the 62-pin connector and the
Note: Diagnostic codes for all of the engine sensors will be ac- ECM.
tive with the 62-pin connector disconnected. Ignore all other Replace the faulty wiring.
diagnostic codes. Only look for 1209 diagnostic codes. Use the electronic service tool to clear all logged diagnostic co-
4 diagnostic code.

wire.
UENR4504 303
i05942917
Sensor Signal (Analog, Active)

- Test
Note: This procedure is applicable to all engine

pressure sensors except the exhaust gas
pressure sensor.
Table 218

Code
102-3 Engine Intake Manifold #1 The Electronic Control Module (ECM) detects the following conditions:
Pressure : Voltage Above
Normal The signal voltage from the intake manifold air pressure sensor is greater than 4.92 V for at least 0.5
seconds.
The ECM will use the default value for the intake manifold air pressure while this code is active. The de-
fault value is 98 kPa (14.2 psi).
102-4 Engine Intake Manifold #1 The ECM detects the following conditions:
Pressure : Voltage Below
Normal The signal voltage from the intake manifold air pressure sensor is less than 0.2 V for at least 0.5
seconds.
The ECM will use the default value for the intake manifold air pressure while this code is active. The de-
fault value is 98 kPa (14.2 psi).
108-3 Barometric Pressure : The ECM detects that the signal voltage from the barometric pressure sensor is greater than 4.9 V for at
Voltage Above Normal least 0.8 seconds. The barometric pressure sensor is contained within the ECM.
The ECM will use the default value for the barometric pressure while this code is active. The default val-
ue is 97 kPa (14 psi).
108-4 Barometric Pressure : The ECM detects that the signal voltage from the barometric pressure sensor is less than 0.2 V for at
Voltage Below Normal least 0.8 seconds. The barometric pressure sensor is contained within the ECM.
The ECM will use the default value for the barometric pressure while this code is active. The default val-
ue is 97 kPa (14 psi).
157-3 Engine Injector Metering The ECM detects that the signal voltage from the fuel rail pressure sensor is greater than 4.9 V for at
Rail #1 Pressure : Voltage least 0.2 seconds.
Above Normal
157-4 Engine Injector Metering The ECM detects that the signal voltage from the intake manifold air pressure sensor is less than 0.34 V
Rail #1 Pressure : Voltage for at least 0.2 seconds.
Below Normal
(continued)
304 UENR4504
(Table 218, contd)


Code
157-10 Engine Injector Metering The ECM detects the following conditions:
Rail #1 Pressure : Abnor-
mal Rate of Change An implausible rate of change in the signal from the fuel rail pressure sensor.
The condition has been detected five times within 3 seconds.
There are no other active diagnostic codes for the fuel rail pressure sensor.
This diagnostic code indicates an intermittent connection in the circuit for the fuel rail pressure sensor.
Pressure : Data Drifted
High The intake manifold pressure is greater than 10 kPa (1.5 psi) above the barometric pressure for at least
5 seconds.
The battery voltage is greater than 10 V.
Pressure : Data Drifted
Low The intake manifold pressure is greater than 10 kPa (1.5 psi) below the barometric pressure for at least
5 seconds.
The battery voltage is greater than 10 V.
The following conditions must exist before any of the

above codes will become active:

to this procedure:
The 5 V sensor supply provides power to all 5 V
sensors. The ECM supplies 5.0 ± 0.1 V to each of the
pressure sensor connectors. The sensor supply is
output short circuit protected. A short circuit to the
battery will not damage the circuit inside the ECM.
Pull-up Voltage
The ECM continuously outputs a pull-up voltage on
the circuit for the sensor signal wire. This pull-up
voltage is required for correct sensor operation and
diagnostics.
When the sensor is disconnected, this pull-up voltage
can be measured at the harness connector for the
sensor.
UENR4504 305
Schematic diagram for the engine pressure sensors

View of the pin locations on the 62-pin engine Typical view of the pin locations on the P2 connector
interface connector for the pressure sensors. for the pressure sensors
(5) Fuel rail pressure sensor ground (10) Intake manifold air pressure sensor 5 V supply
(6) Fuel rail pressure sensor signal (11) Fuel rail pressure sensor 5 V supply
(7) Fuel rail pressure sensor 5 supply (25) Intake manifold air pressure sensor ground
(17) Intake manifold air pressure sensor 5 V supply (26) Fuel rail pressure sensor ground
(18) Intake manifold air pressure sensor signal (40) Intake manifold air pressure sensor signal
(19) Intake manifold air pressure sensor ground (41) Fuel rail pressure sensor signal
306 UENR4504
Table 219
or connector
A. Thoroughly inspect the terminal connections on the P2/J2 Repair the damaged wire or the damaged connector. Replace
ECM connector. Refer to Troubleshooting, “Electrical Connec- any blown fuses
tors - Inspect”. Use the electronic service tool to clear all logged diagnostic co-
B. Thoroughly inspect the connectors for the engine pressure
sensors. Refer to Troubleshooting, “Electrical Connectors - Result: All connectors, pins, and sockets are correctly con-
Inspect”. nected and/or inserted and the harness is free of corrosion, of
abrasion or of pinch points.
C. Perform a 30 N (6.7 lb) pull test on each of the wires in the
ECM connector and the sensor connectors that are associ- Proceed to Test Step 2.
ated with the engine pressure sensors.
the engine pressure sensors back to the ECM.
2. Check For Active Diagnostic Codes Diagnostic Result: A 108-3 or 108-4 diagnostic code is active.
codes
Result: An XXXX-3 or an XXXX-4 diagnostic code is active for
B. Verify if any of the diagnostic codes that are listed in Table one or more of the other pressure sensors.
218 are active. A 102-20 or 102-21 diagnostic code is active.
Result: A 157-10 diagnostic code is active or recently logged.
An intermittent connection exists in the circuit for the fuel rail

pressure sensor.
order to identify intermittent connections.
3. Check the Supply Voltage at the Sensor Connector 4.9 V to 5.1 V Result: The voltage measurement is not within the expected
range.
B. Disconnect the connector for the suspect sensor.
Result: The voltage measurement is within the expected
C. Turn the keyswitch to the ON position. Do not start the range.
engine.
D. Measure the voltage between the 5 V supply terminal and
the ground terminal on the harness connector for the suspect
sensor. The voltage measurement should be 5.0 ± 0.1 V.
F. Reconnect the sensor.
(continued)
UENR4504 307
(Table 219, contd)

4. Check the Supply Voltage at the 62-Pin Connector 4.9 V to 5.1 V Result: The voltage measurement is 5.0 ± 0.1 V.
A. Turn the keyswitch to the OFF position. The fault is in the 5 V supply wire or the ground wire between
the 62-pin engine interface connector and the sensor.
start the engine.
Result: The voltage measurement is not 5.0 ± 0.1 V.
D. Measure the voltage between the 5 V supply terminal and
the ground terminal for the suspect sensor on the 62-pin con- The fault is in the 5 V supply wire or the ground wire between
nector on the harness between the engine and the ECM. The the 62-pin engine interface connector and the ECM.
voltage measurement should be 5.0 ± 0.1 V. Replace the faulty wiring.
E. Turn the keyswitch to the OFF position. nates the fault.
F. Reconnect the 62-pin connector.
5. Verify the Type of Active Diagnostic Code Diagnostic Result: An XXXX-4 diagnostic code is active for one or more of
codes the pressure sensors at this time.
A. Turn the keyswitch to the ON position. Wait at least 10 sec-
B. Use the electronic service tool to check for active diagnostic Result: An XXXX-3 diagnostic code is active for one or more of
codes. Record all active diagnostic codes. the pressure sensors at this time.
C. Determine if the fault is related to an open circuit diagnostic Proceed to Test Step 8.
code or a short circuit diagnostic code.
Result: None of the preceding diagnostic codes are active.
An intermittent fault may exist.

6. Create An Open Circuit at the Sensor Connector Diagnostic Result: An XXXX-3 diagnostic code became active after dis-
codes connecting the sensor.
Temporarily connect a new sensor to the harness, but do not in-
B. Disconnect the connector for the sensor with the XXXX-4 stall the new sensor in the engine. Use the electronic service
diagnostic code. tool in order to verify that the repair eliminates the fault and then
permanently install the new sensor.
C. Turn the keyswitch to the ON position. Wait for at least 10 If the fuel rail is replaced, use the electronic service tool to per-
seconds for activation of the diagnostic codes. form the “Rail Pressure Valve Learn Reset” .
D. Use the electronic service tool to check the “Active Diag- nostic codes.
nostic Code” screen. Check for an XXXX-3 diagnostic code
for the suspect sensor. Result: The XXXX-4 diagnostic code is still active with the sen-
sor disconnected.
(continued)
308 UENR4504
(Table 219, contd)

7. Create an Open Circuit at the 62-Pin Connector Diagnostic Result: An XXXX-3 diagnostic code for the suspect sensor be-
Codes came active after the 62-pin connector was disconnected.
tive with the 62-pin connector disconnected. Ignore all other Result: The XXXX-4 diagnostic code for the suspect sensor is
diagnostic codes and only look for codes relating to the sus- still active with the 62-pin connector disconnected.
pect sensor.
The fault is in the wiring between the 62-pin connector and the
D. Access the “Active Diagnostic Codes” screen on the elec- ECM.
tronic service tool and check for an active XXXX-3 diagnostic Replace the faulty wiring.
code for the suspect sensor. Use the electronic service tool to clear all logged diagnostic co-
8. Create a Short at the Sensor Connector Diagnostic Result: An XXXX-4 diagnostic code was active with the jumper
codes installed.
Temporarily connect a new pressure sensor to the harness, but
B. Disconnect the connector for the suspect sensor. do not install the new sensor in the engine. Use the electronic
service tool in order to verify that the repair eliminates the fault
C. Fabricate a jumper wire that is 150 mm (6 inch) long. Install and then permanently install the new sensor.
the jumper wire between the sensor signal terminal and the If the fuel rail is replaced, use the electronic service tool to per-
sensor ground terminal on the harness connector for the sus- form the “Rail Pressure Valve Learn Reset” .
pect sensor. Use the electronic service tool to clear all logged diagnostic co-
onds for activation of the diagnostic codes. Result: An XXXX-3 diagnostic code is still active with the jump-
er installed.
E. Use the electronic service tool to check for an active XXXX-
4 diagnostic code for the suspect sensor. Proceed to Test Step 9.

wire.
(continued)
UENR4504 309
(Table 219, contd)

9. Create a Short at the 62-Pin Connector Diagnostic Result: An XXXX-4 diagnostic code was active with the jumper
codes installed.
the jumper wire between the suspect sensor signal terminal des and verify that the repair eliminates the fault.
and the sensor ground terminal on the 62-pin connector on
the harness between the engine and the ECM. Result: An XXXX-3 diagnostic code is still active with the jump-
er installed.
diagnostic codes. Only look for codes that relate to the sus- Use the electronic service tool to clear all logged diagnostic co-
pect sensor. des and verify that the repair eliminates the fault.

4 diagnostic code for the suspect sensor.

wire.
codes ment ECM.
B. If the DSN recommends the use of a replacement ECM, in- pect ECM, replace the ECM.
stall a replacement ECM. Refer to Troubleshooting, “Replac- Use the electronic service tool in order to clear all logged diag-
ing the ECM”. nostic codes and then verify that the repair eliminates the fault.
Contact the DSN.
If the procedure did not correct the fault, contact the DSN.
i05943085
Sensor Signal (Analog,

Passive) - Test
310 UENR4504
Table 220
Diagnostic Trouble Codes for the Engine Temperature Sensors

Code
105-3 Engine Intake Manifold #1 The Electronic Control Module (ECM) detects the following conditions:
Temperature : Voltage
Above Normal The signal voltage for the intake manifold temperature sensor is greater than 4.94 VDC for at least 0.5
seconds.
Temperature : Voltage Below
Normal The signal voltage for the intake manifold temperature sensor is less than 0.2 VDC for at least 0.5
seconds.
110-3 Engine Coolant Temperature The ECM detects that the signal voltage for the coolant temperature sensor is greater than 4.93 VDC
: Voltage Above Normal for at least 0.5 seconds.
The ECM will use the default value for the coolant temperature while this diagnostic code is active. The
default value is −10° C (14° F) at engine start, gradually increasing to 90° C (194° F) as the engine is
running.
110-4 Engine Coolant Temperature The ECM detects that the signal voltage for the coolant temperature sensor is less than 0.2 VDC for at
: Voltage Below Normal least 0.5 seconds.
The ECM will use the default value for the coolant temperature while this diagnostic code is active. The
default value is −10° C (14° F) at engine start, gradually increasing to 90° C (194° F) as the engine is
running.
172-3 Engine Air Inlet Temperature The ECM detects that the signal voltage for the air inlet temperature sensor is greater than 4.93 VDC
: Voltage Above Normal for at least 0.5 seconds.
While this code is active, the ECM will gradually increase or decrease the air inlet temperature from the
last valid reading until the default value is reached. The default value is 30° C (86° F).
172-4 Engine Air Inlet Temperature The ECM detects that the signal voltage for the air inlet temperature sensor is less than 0.2 VDC for at
: Voltage Below Normal least 0.5 seconds.
While this code is active, the ECM will gradually increase or decrease the air inlet temperature from the
last valid reading until the default value is reached. The default value is 30° C (86° F).
173-3 Engine Exhaust Gas Tem- The ECM detects the following conditions:
perature : Voltage Above
Normal The signal from the exhaust gas temperature sensor is greater than 3.6 VDC for at least 1 second.
While this code is active, the ECM will use the default value for the exhaust gas temperature. The de-
fault value is 350° C (662° F).
The warning lamp will come on. The engine will be derated.
(continued)
UENR4504 311
(Table 220, contd)


Code
173-4 Engine Exhaust Gas Tem- The ECM detects that the signal from the exhaust gas temperature sensor is less than 0.46 VDC for at
perature : Voltage Below least 1 second.
Normal
While this code is active, the ECM will use the default value for the exhaust gas temperature. The de-
fault value is 350° C (662° F).
The warning lamp will come on. The engine will be derated.
174-3 Engine Fuel Temperature 1 : The ECM detects that the signal voltage for the fuel temperature sensor is greater than 4.93 VDC for at
Voltage Above Normal least 0.5 seconds.
The ECM will use a default value for the fuel temperature while this code is active. The default value
will be based on the coolant temperature. If the coolant temperature sensor has an active fault, the de-
fault value for the fuel temperature is 40° C (104° F).
174-4 Engine Fuel Temperature 1 : The ECM detects that the signal voltage for the fuel temperature sensor is less than 0.2 VDC for at
Voltage Below Normal least 0.5 seconds.
The ECM will use a default value for the fuel temperature while this code is active. The default value
will be based on the coolant temperature. If the coolant temperature sensor has an active fault, the de-
fault value for the fuel temperature is 40° C (104° F).
4360-3 Aftertreatment #1 SCR Cata- The ECM detects that the signal voltage for the Selective Catalytic Reduction (SCR) inlet temperature
lyst Intake Gas Temperature sensor is greater than 3.6 VDC for at least 1 second.
The ECM will use the default value for the SCR inlet temperature while this code is active. The default
temperature is 0.06° C (32.1° F).
4360-4 Aftertreatment #1 SCR Cata- The ECM detects that the signal voltage for the SCR inlet temperature sensor is less than 0.46 VDC
lyst Intake Gas Temperature for at least 1 second.
The ECM will use the default value for the SCR inlet temperature while this code is active. The default
temperature is 0.06° C (32.1° F).
4363-3 Aftertreatment #1 SCR Cata- The ECM detects that the signal voltage for the Selective Catalytic Reduction (SCR) outlet temperature
lyst Outlet Gas Temperature sensor is greater than 3.3 VDC for at least 1 second.
The ECM will use the default value for the SCR outlet temperature while this code is active. The default
temperature is 41° C (106° F).
4363-4 Aftertreatment #1 SCR Cata- The ECM detects that the signal voltage for the SCR outlet temperature sensor is less than 0.2 VDC
lyst Outlet Gas Temperature for at least 1 second.
The ECM will use the default value for the SCR outlet temperature while this code is active. The default
temperature is 41° C (106° F).
(continued)
312 UENR4504
(Table 220, contd)


Code
4765-3 Aftertreatment #1 Diesel Oxi- The ECM detects that the signal voltage for the Diesel Oxidation Catalyst (DOC) inlet temperature sen-
dation Catalyst Intake Gas sor is greater than 3.6 VDC for at least 1 second.
Temperature : Voltage
Above Normal The ECM will use the default value for the DOC inlet temperature sensor while this code is active. The
default value is 80° C (176° F).
4765-4 Aftertreatment #1 Diesel Oxi- The ECM detects that the signal voltage for the DOC inlet temperature sensor is less than 0.46 VDC
dation Catalyst Intake Gas for at least 1 second.
Temperature : Voltage Below
Normal The ECM will use the default value for the DOC inlet temperature sensor while this code is active. The
default value is 80° C (176° F).
This procedure covers open circuit diagnostic codes

and short circuit diagnostic codes that are associated
with the following sensors:
• Intake manifold temperature sensor

• Exhaust gas temperature sensor

• Fuel temperature sensor
• Air inlet temperature sensor

• DOC inlet temperature sensor
• SCR inlet temperature sensor

• SCR outlet temperature sensor
to this procedure:
The troubleshooting procedures for the diagnostic
codes of each temperature sensor are identical. The
temperature sensors have two terminals. The signal
voltage from each sensor is supplied to the
appropriate terminal in the P2/J2 connector or the P1/
J1 connector.
Pull-up Voltage
The ECM continuously outputs a pull-up voltage on
the circuit for the sensor signal wire. This pull-up
voltage is required for correct sensor operation and
diagnostics.
When the sensor is disconnected, this pull-up voltage
can be measured at the harness connector for the
sensor.
UENR4504 313

Schematic diagram for the engine temperature sensors

Typical view of the pin locations for the temperature Typical view of the P2 pin locations for the
sensors on the 62-pin engine interface connector temperature sensors
(13) Coolant temperature sensor ground (23) Engine fuel temperature sensor ground
(14) Coolant temperature sensor signal (25) Intake manifold temperature sensor ground
(15) Fuel temperature sensor ground (27) Exhaust gas temperature sensor ground
(16) Fuel temperature sensor signal (38) Engine fuel temperature sensor signal
(19) Intake manifold temperature sensor ground (43) Exhaust gas temperature sensor signal
(20) Intake manifold temperature sensor signal (55) Intake manifold temperature sensor signal
(25) Exhaust gas temperature sensor signal (57) Coolant temperature sensor signal
(26) Exhaust gas temperature sensor ground (58) Intake manifold temperature sensor ground
314 UENR4504

Typical view of the P1 pin locations for the
temperature sensors
(19) Air inlet temperature sensor signal
(20) Air inlet temperature sensor ground
(56) DOC inlet temperature sensor signal
(65) DOC inlet temperature sensor ground
(79) SCR outlet temperature sensor ground
(80) SCR outlet temperature sensor signal
(81) SCR inlet temperature sensor ground
(82) SCR inlet temperature sensor signal
Table 221
or connector
and P1/J1 ECM connectors. Refer to Troubleshooting, “Elec- Use the electronic service tool to clear all logged diagnostic co-
trical Connectors - Inspect”. des. Verify that the repair eliminates the fault.
B. Thoroughly inspect the connectors for the engine tempera- Result: All connectors, pins, and sockets are correctly con-
ture sensors. Refer to Troubleshooting, “Electrical Connectors nected and/or inserted and the harness is free of corrosion, of
- Inspect”. abrasion or of pinch points.
ECM connector and the sensor connectors that are associ-
ated with the engine temperature sensors.
the engine temperature sensors back to the ECM.
2. Check For Active Diagnostic Codes Diagnostic Result: An XXXX-4 diagnostic code is active for one of the en-
codes gine temperature sensors.
A. Turn the keyswitch to the ON position. Wait at least 10 sec-
B. Verify if any of the diagnostic codes that are listed in Table Result: An XXXX-3 diagnostic code is active for one or more of
220 are active. the engine temperature sensors.
(continued)
UENR4504 315
(Table 221, contd)

3. Create An Open Circuit at the Sensor Connector Diagnostic Result: An XXXX-3 diagnostic code became active after dis-
codes connecting the sensor.
B. Disconnect the connector for the sensor with the XXXX-4 stall the new sensor in the engine. Use the electronic service
diagnostic code. tool in order to verify that the repair eliminates the fault and then
permanently install the new sensor.
C. Turn the keyswitch to the ON position. Wait for at least 10 Use the electronic service tool in order to clear all logged diag-
seconds for activation of the diagnostic codes. nostic codes.
D. Use the electronic service tool to check the “Active Diag- Result: The XXXX-4 diagnostic code is still active with the sen-
nostic Code” screen. Check for an XXXX-3 diagnostic code sor disconnected.
for the suspect sensor.
If the sensor is connected to the P1/J1 ECM connector, the fault
is in the wiring between the suspect sensor and the ECM.
If the sensor is connected to the P2/J2 ECM connector, pro-

4. Create an Open Circuit at the 62-Pin Connector Diagnostic Result: An XXXX-3 diagnostic code for the suspect sensor be-
Codes came active after the 62-pin connector was disconnected.
tive with the 62-pin connector disconnected. Ignore all other Result: The XXXX-4 diagnostic code for the suspect sensor is
diagnostic codes and only look for codes relating to the sus- still active with the 62-pin connector disconnected.
pect sensor.
D. Access the “Active Diagnostic Codes” screen on the elec- ECM.
tronic service tool and check for an active XXXX-3 diagnostic Replace the faulty wiring.
code for the suspect sensor. Use the electronic service tool to clear all logged diagnostic co-
(continued)
316 UENR4504
(Table 221, contd)

5. Create a Short at the Sensor Connector Diagnostic Result: An XXXX-4 diagnostic code was active with the jumper
codes installed.
B. Disconnect the connector for the suspect sensor. stall the new sensor in the engine. Use the electronic service
tool in order to verify that the repair eliminates the fault and then
C. Fabricate a jumper wire that is 150 mm (6 inch) long. Install permanently install the new sensor.
the jumper wire between the sensor signal terminal and the Use the electronic service tool to clear all logged diagnostic co-
sensor ground terminal on the harness connector for the sus- des and verify that the repair eliminates the fault.
pect sensor.
Result: An XXXX-3 diagnostic code is still active with the jump-
D. Turn the keyswitch to the ON position. Wait at least 10 sec- er installed.
If the sensor is connected to the P1/J1 ECM connector, the fault
E. Use the electronic service tool to check for an active XXXX- is in the wiring between the suspect sensor and the ECM.
4 diagnostic code for the suspect sensor. Replace the faulty wiring.
F. Turn the keyswitch to the OFF position. Remove the jumper des and verify that the repair eliminates the fault.
wire.
If the sensor is connected to the P2/J2 ECM connector, pro-
6. Create a Short at the 62-Pin Connector Diagnostic Result: An XXXX-4 diagnostic code was active with the jumper
codes installed.
the jumper wire between the suspect sensor signal terminal des and verify that the repair eliminates the fault.
and the sensor ground terminal on the 62-pin connector on
the harness between the engine and the ECM. Result: An XXXX-3 diagnostic code is still active with the jump-
er installed.
diagnostic codes. Only look for codes that relate to the sus- Use the electronic service tool to clear all logged diagnostic co-
pect sensor. des and verify that the repair eliminates the fault.

4 diagnostic code for the suspect sensor.

wire.
i05944906
Solenoid Valve - Test

(Coolant Diverter Valve)
UENR4504 317
Table 222
Diagnostic Trouble Codes for the Solenoid Valves

Code
3363-5 Aftertreatment #1 DEF Tank The ECM detects the following conditions:
Heater : Current Below
Normal A low current condition in the output from the ECM to the solenoid for the coolant diverter valve for at
least 0.01 seconds.
3363-6 Aftertreatment #1 DEF Tank The ECM detects the following conditions:
Heater : Current Above
Normal A high current condition in the output from the ECM to the solenoid for the coolant diverter valve for at
least 0.2 seconds.

to this procedure:
Coolant Diverter Valve

When the coolant diverter valve is activated, the
engine coolant is diverted through the Diesel Exhaust
Fluid (DEF) tank in order to maintain the correct DEF
temperature for dosing.

Schematic diagram for the coolant diverter valve
318 UENR4504

coolant diverter valve
(7) Coolant diverter valve return
Table 223
A. Check the fuses.
B. Thoroughly inspect the P1/J1 ECM connector and thor- any blown fuses
oughly inspect the connector for the coolant diverter valve. Use the electronic service tool to clear all logged diagnostic co-
Refer to Troubleshooting, “Electrical Connector - Inspect” for des. Verify that the repair eliminates the fault.
details.
C. Perform a 30 N (6.7 lb) pull test on each of the wires that nected and/or inserted and the harness is free of corrosion, of
are associated with the coolant diverter valve. abrasion or of pinch points.
2. Check for Diagnostic Codes Diagnostic Result: A 3363-5 diagnostic code is active or recently logged.
codes
B. Connect the electronic service tool to the diagnostic Result: A 3363-6 diagnostic code is active or recently logged.
connector.
C. Run the engine.

des and/or logged diagnostic codes.
3. Check the Power Supply to the Coolant Diverter Valve 10 V to 14 V Result: The measured voltage is not within the expected
range.
B. Disconnect the connector for the coolant diverter valve.
(continued)
UENR4504 319
(Table 223, contd)

4. Check the Wiring Between the Coolant Diverter Valve Less than 5 Result: The measured resistance is greater than 5 Ohms.
and the SCR Relay Ohms
Check the fuse. If the fuse is OK, the fault is in the wiring be-
A. Turn the keyswitch to the OFF position. tween the coolant diverter valve and the SCR relay.
B. Disconnect the connector for the coolant diverter valve. Dis- Use the electronic service tool to clear all logged diagnostic co-
connect the SCR relay. des and verify that the repair eliminates the fault.
C. Use a multimeter to measure the resistance between termi- Result: The measured resistance is less than 5 Ohms.
nal 1 on the harness connector for the coolant diverter valve
and terminal 87 on the harness connector for the SCR relay. Test the circuit for the SCR relay. Refer to Troubleshooting,
“Relay - Test (SCR Relay)”.
5. Create a Short Circuit at the Coolant Diverter Valve Diagnostic Result: A 3363-6 diagnostic code is active when the jumper is
Connector codes installed.
A. Turn the keyswitch to the OFF position. Install a replacement coolant diverter valve.
B. Disconnect the connector for the coolant diverter valve. des and verify that the repair eliminates the fault.
C. Fabricate a jumper wire that is 150 mm (6 inch) long. Install Result: A 3363-5 diagnostic code is still active with the jumper
the jumper wire between terminal 1 and terminal 2 on the har- installed.
ness connector for the coolant diverter valve.
The fault is in the wiring between the coolant diverter valve and
D. Run the engine. Check for active diagnostic codes on the the ECM.
electronic service tool. Wait at least 30 seconds for activation Replace the faulty wiring.
of the diagnostic codes. Use the electronic service tool to clear all logged diagnostic co-
6. Create an Open Circuit at the Solenoid Diagnostic Result: A 3363-5 diagnostic code is active with the valve
codes disconnected.
Install a replacement coolant diverter valve.
B. Disconnect the connector for the coolant diverter valve. Use the electronic service tool to clear all logged diagnostic co-
C. Run the engine. Check for active diagnostic codes on the
electronic service tool. Wait at least 30 seconds for activation Result: A 3363-6 diagnostic code is still active with the valve
of the diagnostic codes. disconnected.
D. Turn the keyswitch to the OFF position. The fault is in the wiring between the coolant diverter valve and
the ECM.
If the procedure does not correct the fault, contact the Dealer Solution Network (DSN).
i05944100
Solenoid Valve - Test

320 UENR4504
Table 224
Diagnostic Trouble Codes for the Solenoid Valves

Code
1076-2 Engine Fuel Injection Pump The Electronic Control Module (ECM) detects an intermittent open or short circuit error in the control
Fuel Control Valve : Erratic, circuit for the fuel metering valve on the high-pressure fuel pump.
This diagnostic code will not be active if a continuous fault in the circuit is detected.
1076-5 Engine Fuel Injection Pump The ECM detects the following conditions:
Fuel Control Valve : Current
Below Normal A low current condition in the output from the ECM to the solenoid for the fuel metering valve on the
high-pressure fuel pump for at least 0.01 seconds.
The battery voltage is at least 9.5 VDC.
1076-6 Engine Fuel Injection Pump The ECM detects the following conditions:
Fuel Control Valve : Current
Above Normal A high current condition in the output from the ECM to the solenoid for the fuel metering valve on the
high-pressure fuel pump for at least 0.01 seconds.
The battery voltage is at least 9.5 VDC.
1188-5 Engine Turbocharger Waste- The ECM detects the following conditions:
gate Actuator 1 Position :
Current Below Normal A low current condition in the output from the ECM to the solenoid for the wastegate regulator for at
least 0.2 seconds.
1188-6 Engine Turbocharger Waste- The ECM detects the following conditions:
gate Actuator 1 Position :
Current Above Normal A high current condition in the output from the ECM to the solenoid in the wastegate regulator for at
least 0.2 seconds.
The following background information is related Fuel metering valve for the high-pressure fuel
to this procedure: pump:
The high-pressure fuel pump is equipped with a fuel
Electronically controlled wastegate metering valve. The fuel metering valve precisely
controls the amount of fuel that enters the high-
The engine has a turbocharger with an electronically pressure fuel pump.
controlled wastegate. Typically, the wastegate is a
mechanical valve that is used in the turbocharger in The amount of fuel that is required is calculated by
order to regulate the intake manifold pressure to a set the software that is contained in the ECM. The
value. solenoid in the suction control valve is controlled by a
PWM signal from the ECM.
The control system for the electronically controlled
wastegate precisely regulates the intake manifold
pressure by using a wastegate regulator to control the
wastegate.
The required intake manifold pressure is calculated
by the software that is contained in the ECM. The
ECM uses the wastegate regulator to control the
wastegate in order to provide the precise value of
intake manifold pressure. The solenoid in the
wastegate regulator is controlled by a PWM signal.
UENR4504 321

Schematic diagram for the solenoid valves

View of the pin locations on the P2 connector for the View of the pin locations on the P1 connector
solenoid valves (1) Battery (+)
(4) Wastegate regulator return (28) Main relay control
(15) Fuel metering valve supply
(60) Fuel metering valve return
322 UENR4504
Table 225
A. Check the fuses.
B. Thoroughly inspect the P2/J2 and P1/J1 ECM connectors any blown fuses
and thoroughly inspect the connectors for the solenoid valves. Use the electronic service tool to clear all logged diagnostic co-
Refer to Troubleshooting, “Electrical Connector - Inspect” for des. Verify that the repair eliminates the fault.
details.
C. Thoroughly inspect the 62-pin connector . Refer to Trouble- nected and/or inserted and the harness is free of corrosion, of
shooting, “Electrical Connectors - Inspect” for details. abrasion or of pinch points.
D. Perform a 30 N (6.7 lb) pull test on each of the wires that Proceed to Test Step 2.
are associated with the solenoid valves.
2. Check for Diagnostic Codes Diagnostic Result: A 1076-5 diagnostic code is active or recently logged.
codes
B. Connect the electronic service tool to the diagnostic Result: A 1188-5 diagnostic code is active or recently logged.
connector.
Result: A 1076-6 or 1188-6 diagnostic code is active or re-
D. Monitor the electronic service tool for active diagnostic co- cently logged.
des and/or logged diagnostic codes.
Result: A 1076-2 diagnostic code is active or recently logged
An intermittent fault exists in the circuit for the fuel metering

valve.
For intermittent faults, refer to Troubleshooting, “Electrical Con-
nectors - Inspect”.
3. Check the Power Supply to the ECM Power supply Result: The power supply to P1:1 is faulty.
A. Check that pin P1:1 is receiving the correct voltage. Refer Perform any necessary repairs. Refer to Troubleshooting,
to Troubleshooting, “Electrical Power Supply - Test”. “Electrical Power Supply - Test”.
Note: The power supply for the fuel pump metering valve is Result: The power supply to P1:1 is OK.
supplied through P1:1.
(continued)
UENR4504 323
(Table 225, contd)

4. Create a Short Circuit in the Harness at the Solenoid Diagnostic Result: An XXXX-6 diagnostic code is active when the jumper
codes is installed.
Temporarily connect a replacement for the suspect valve to the
B. Disconnect the connector for the suspect solenoid. harness.
Turn the keyswitch to the ON position. Use the electronic serv-
C. Fabricate a jumper wire that is 150 mm (6 inch) long. ice tool in order to check for active diagnostic codes. Wait at
least 30 seconds in order for the codes to be displayed.
D. Install the wire between the two pins on the harness con- If the fault is eliminated, reconnect the suspect valve. If the fault
nector for the suspect solenoid in order to create a short returns, permanently install the replacement valve. Refer to
circuit. Disassembly and Assembly for the correct procedure.
E. Turn the keyswitch to the ON position. Check for active di- Result: An XXXX-5 diagnostic code is still active with the jump-
agnostic codes on the electronic service tool. er installed.
F. Remove the jumper wire from the connector for the solenoid Proceed to Test Step 5.
valve.
5. Create a Short Circuit at the 62-Pin Connector Diagnostic Result: An XXXX-6 diagnostic code is active when the jumper
codes is installed.
The fault is in the supply wire or the return wire for the suspect
B. Disconnect the 62-pin connector. valve between the valve and the 62-pin connector.
the jumper wire between the supply and return terminals on des and verify that the repair eliminates the fault.
the 62-pin connector on the harness between the engine and
the ECM. Result: A 1076-5 diagnostic code is still active with the jumper
installed.
D. Turn the keyswitch to the ON position. Check for active di-
agnostic codes on the electronic service tool. Wait at least 30 Proceed to Test Step 6.
seconds for activation of the diagnostic codes.
Note: Diagnostic codes for all of the engine sensors will be ac- Result: A 1188-5 diagnostic code is still active with the jumper
tive with the 62-pin connector disconnected. Ignore all other installed.
codes and only look for codes that relate to the suspect valve.
(continued)
324 UENR4504
(Table 225, contd)

6. Create a Short Circuit at the ECM Connector Diagnostic Result: A 1076-6 diagnostic code is active with the jumper
codes installed.
The fault is in the harness between the 62-pin connector and
B. Disconnect the P2 connector from the ECM. the ECM.
Replace the faulty wiring. Use the electronic service tool to
C. Fabricate a jumper wire and install the jumper wire between clear all logged diagnostic codes and verify that the repair elimi-
J2:15 and J2:60. nates the fault.
D. Turn the keyswitch to the ON position. Result: The 1076-5 diagnostic code is still active with the jump-
er installed.
E. Use the electronic service tool to check for an active 1076
diagnostic code. Wait at least 30 seconds for activation of the Proceed to Test Step 12.
diagnostic codes.
H. Reconnect the connectors.
7. Measure the Voltage at the Wastegate Regulator 10 V to 14 V Result: The measured voltage is not within the expected
Connector range.
A. Turn the keyswitch to the OFF position. Check the fuse. If the fuse is blown, there is a short circuit in
the switched battery supply to the wastegate regulator
B. Disconnect the wastegate regulator. connector.
If the fuse is not blown, there is an open circuit in the switched
C. Turn the keyswitch to the ON position. battery supply to the wastegate regulator connector.
Repair the faulty wiring or replace the faulty wiring. Use the
D. Use a multimeter to measure the voltage between terminal electronic service tool to clear all logged diagnostic codes and
1 on the harness connector for the wastegate regulator and a verify that the repair eliminates the fault.
suitable ground.
8. Check the Wastegate Regulator Return Wire for an Less than 5 Result: The measured resistance is greater than 5 Ohms.
Open Circuit Ohms
The fault is in the wiring between terminal 27 on the 62-pin con-
A. Turn the keyswitch to the OFF position. nector and P2:4.
B. Disconnect the wastegate regulator and the P2 connector. clear all logged diagnostic codes and verify that the repair elimi-
nates the fault.
C. Use a suitable multimeter to measure the resistance be-
tween P2:4 and pin 27 on the 62-pin connector on the harness Result: The measured resistance is less than 5 Ohms.
between the engine and the ECM.
(continued)
UENR4504 325
(Table 225, contd)

9. Create an Open Circuit at the Solenoid Diagnostic Result: An XXXX-5 diagnostic code is active with the valve
codes disconnected.
Temporarily connect a replacement for the suspect valve to the
B. Disconnect the connector for the suspect solenoid valve. harness.
Turn the keyswitch to the ON position. Use the electronic serv-
C. Turn the keyswitch to the ON position. Check for active di- ice tool in order to check for active diagnostic codes. Wait at
agnostic codes on the electronic service tool. Wait at least 30 least 30 seconds in order for the codes to be displayed.
seconds for activation of the diagnostic codes. If the fault is eliminated, reconnect the suspect valve. If the fault
returns, permanently install the replacement valve. Refer to
D. Turn the keyswitch to the OFF position. Disassembly and Assembly for the correct procedure.
Result: An XXXX-6 diagnostic code is still active with the valve

disconnected.
10. Create an Open Circuit at the 62-Pin Connector Diagnostic Result: An XXXX-5 diagnostic code is active with the 62-pin
codes connector disconnected.
The fault is in the wiring for the suspect valve between the valve
B. Disconnect the 62-pin connector. and the 62-pin connector.
C. Turn the keyswitch to the ON position. Check for active di- Use the electronic service tool to clear all logged diagnostic co-
agnostic codes on the electronic service tool. des and verify that the repair eliminates the fault.
tive with the 62-pin connector disconnected. Ignore all other Result: An XXXX-6 diagnostic code is still active with the 62-
codes and only look for codes that relate to the suspect valve. pin connector disconnected.
11. Create an Open Circuit at the ECM Diagnostic Result: An XXXX-5 diagnostic code is active with the P2 con-
B. Disconnect the P2 connector from the ECM. P2 connector.
C. Turn the keyswitch to the ON position. Wait at least 30 sec- clear all logged diagnostic codes and verify that the repair elimi-
onds for activation of the diagnostic codes. nates the fault.
D. Use the electronic service tool to check for active diagnos- Result: The XXXX-6 diagnostic code is still active with the P2
tic codes. connector disconnected.
tive with the P2 connector disconnected. Ignore all other co- Proceed to Test Step 12.
codes ment ECM.
B. If the DSN recommends the use of a replacement ECM, in- pect ECM, replace the ECM.
stall a replacement ECM. Refer to Troubleshooting, “Replac- Use the electronic service tool in order to clear all logged diag-
ing the ECM”. nostic codes and then verify that the repair eliminates the fault.
Contact the DSN.
326 UENR4504
i05944991
Speed Control (Analog) - Test

Table 226
Diagnostic Trouble Codes for the Analog Throttle Position Sensors

Code
91-3 Accelerator Pedal Position 1 : Voltage The Electronic Control Module (ECM) detects that the signal from the throttle position sen-
Above Normal sor is greater than the upper diagnostic limit for at least 0.2 seconds.
29-3 Accelerator Pedal Position 2: Voltage
Above Normal
91-4 Accelerator Pedal Position 1 : Voltage Be- The ECM detects that the signal from the throttle position sensor is less than the lower di-
low Normal agnostic limit for at least 0.2 seconds.
29-4 Accelerator Pedal Position 2: Voltage Be-
low Normal
If a fault occurs with the primary throttle and a The sensor receives +5 V power from the ECM. The
secondary throttle is installed, the engine will use the sensor will produce a raw signal voltage that will alter
secondary throttle until the fault is repaired. between low idle and high idle.
If a fault occurs with the secondary throttle, the The sensor senses the speed requirement from the
engine will use the primary throttle until the fault is throttle position. A second sensor may override this
repaired. speed requirement from the first sensor. This override
will be subject to an input from a secondary throttle or
If a functional throttle is not available, the following from the SAE J1939 (CAN) data link or from a PTO
conditions will occur: control.
• The engine will default to the limp home speed. Use the electronic service tool in order to check the
input status.
• If the engine speed is higher than the limp home
speed, the engine will decelerate to the limp home
speed.
• If the engine speed is lower than the limp home

speed, the engine speed will remain at the current
speed.
• The engine will remain at this speed while the
diagnostic code remains active.
• All inputs from the faulty throttle are ignored by the

ECM until the fault is repaired.
• All inputs from the repaired throttle will be ignored
by the ECM until the keyswitch has been cycled.
The diagnostic codes above relate to an analog
sensor. Use this procedure only if the analog sensor
uses an output from a variable resistor.
The sensor is most likely to be mounted on a throttle
pedal. The sensor is attached directly to the throttle
assembly. The sensor provides an output voltage to
the ECM. The sensor output voltage will vary with the
position of the throttle. Foot operated or hand
operated throttle assemblies are available.
UENR4504 327

View of the P1 pin locations for the analog throttle
position sensors
(16) 5 V supply (throttle 1)
(17) 5 V supply (throttle 2)
(38) Throttle 1 ground
(39) Throttle 2 ground
(60) Throttle 1 position
(61) Throttle 2 position
328 UENR4504
Table 227
or connector
A. Turn the keyswitch to the OFF position. Repair the damaged wire or the damaged connector. Replace
any blown fuses
B. Check the connectors and the harness for the following Use the electronic service tool to clear all logged diagnostic co-
faults: des. Verify that the repair eliminates the fault.
· Abrasion
· Corrosion Result: All connectors, pins, and sockets are correctly con-
· Incorrect attachment nected and/or inserted and the harness is free of corrosion, of
Refer to Troubleshooting, “Electrical Connectors - Inspect”. abrasion or of pinch points.
harness that are associated with the throttle position sensor.
Check the wire connectors at the ECM and at the throttle
sensor.
the sensors back to the ECM.
2. Check For Active Diagnostic Codes Diagnostic Result: One or more of the diagnostic codes that are listed in
codes Table 226 is active or recently logged.
B. Use the electronic service tool to check for diagnostic
codes. Result: There are no active or recently logged diagnostic co-
des for the analog throttle position sensors.
3. Check the Throttle Position with the Electronic Service 0 percent at low Result: The throttle output is 0 percent at low idle and 100 per-
Tool idle cent at high idle.
A. Connect the electronic service tool to the diagnostic 100 percent at Proceed to Test Step 4.
connector. high idle
Result: The throttle output is not correct.
engine. Use the electronic service tool to verify that the throttle has
been configured correctly before continuing with this procedure.
C. Observe the throttle position reading on the throttle status For information on the parameters that can be configured, refer
screens in the electronic service tool. to Troubleshooting, “Throttle Setup”.
If the fault is still present after the throttle has been configured
D. Operate the throttle over the full range of movement. correctly, replace the analog throttle position sensor.
(continued)
UENR4504 329
(Table 227, contd)

4. Check the Throttle Selection Status with the Electronic Switch status Result: If the status of the throttle selection switch is shown in
Service Tool the OFF position, then the throttle 1 has control of the engine
speed.
A. Check the status of the throttle selection switch (if If the throttle selection switch status is shown in the ON posi-
equipped). Use the electronic service tool in order to check tion, then the throttle 2 has control of the engine speed.
the status of the throttle selection switch.
The throttle selection switch is operating correctly.
Note: The control of the engine speed may not switch be- There may be an intermittent fault. Refer to Troubleshooting,
tween throttles unless both throttles are in the low idle “Electrical Connectors - Inspect” in order to identify intermittent
position. faults.
The throttle may be overridden by using the SAE J1939 (CAN)
data link or a PTO control. Result: The incorrect throttle is selected.
Change to the other throttle. There may be a fault with the se-
lector switch input.
Check the connections between the throttle selection switch
and P1:62 and battery -. Refer to Troubleshooting, “Electrical
Connectors - Inspect”.
5. Check the Voltage at the Sensor 4.9 V to 5.1 V Result: The measured voltage is not within the expected
range.
The fault is in the 5 V supply wire or the ground wire between
B. Disconnect the connector for the suspect throttle position the throttle position sensor and the ECM.
sensor. Replace the faulty wiring.
C. Turn the keyswitch to the ON position. des and verify that the repair eliminates the fault.
D. Measure the voltage between the 5 V terminal and the sen- Result: The measured voltage is within the expected range.
sor ground terminal on the harness connector for the sensor.
6. Verify the Type of Active Diagnostic Code Diagnostic Result: An XX-3 diagnostic code is active at this time.
codes
Result: An XX-4 diagnostic code is active at this time.
Result: There are no active diagnostic codes for the throttle po-
sition sensors.

cal Connectors - Inspect”.
(continued)
330 UENR4504
(Table 227, contd)

7. Create an Open Circuit at the Sensor Connector Diagnostic Result: An XX-4 diagnostic code became active after discon-
Codes necting the sensor.
Install a replacement sensor.
B. Disconnect the throttle position sensor with the XX-3 diag- Use the electronic service tool to clear all logged diagnostic co-
nostic code. des and verify that the repair eliminates the fault.
C. Turn the keyswitch to the ON position. Wait for at least 10 Result: There is still an active XX-3 diagnostic code with the
seconds for activation of the diagnostic codes. sensor disconnected.
D. Use the electronic service tool to check the “Active Diag- Proceed to Test Step 8.
nostic Code” screen. Check for an XX-4 diagnostic code.
8. Check for a Short Circuit in the Wiring for the Sensor Greater than 1 k Result: At least one of the resistance measurements is greater
Ohm than 1 k Ohm.
There is a short in the wiring for the sensor.
B. Disconnect the suspect throttle position sensor. Disconnect Replace the faulty wiring.
the P1 connector from the ECM. Use the electronic service tool to clear all logged diagnostic co-
tween the sensor signal terminal on the P1 connector and all Result: All resistance measurements are greater than 1 k
other terminals on the P1 connector. Ohm.
9. Create a Short Circuit at the Sensor Connector Diagnostic Result: An XX-3 diagnostic code is active when the jumper is
codes installed.
Install a replacement sensor.
B. Disconnect the connector for the throttle position sensor Use the electronic service tool to clear all logged diagnostic co-
with the XX-4 diagnostic code. des and verify that the repair eliminates the fault.
C. Fabricate a jumper wire that is 150 mm (6 inch) long. Result: An XX-4 diagnostic code remains active when the
jumper is installed.
D. Insert one end of the jumper wire into the terminal for the 5
V supply on the harness connector for the suspect sensor. In- Proceed to Test Step 10.
sert the other end of the jumper wire into the signal terminal on
the harness connector for the suspect sensor.
E. Turn the keyswitch to the ON position
F. Access the “Active Diagnostic Codes” screen on the elec-

tronic service tool and check for an active XX-3 diagnostic
code for the suspect sensor.
G. Remove the jumper.
(continued)
UENR4504 331
(Table 227, contd)

10. Check the Sensor Signal Wire for an Open Circuit Less than 5 Result: The measured resistance is greater than 5 Ohms.
Ohms
A. Turn the keyswitch to the OFF position. There is an open circuit or high resistance in the sensor signal
wire between the sensor connector and the P1 connector.
B. Disconnect the suspect throttle position sensor connector. Replace the faulty wiring.
Disconnect the P1 connector from the ECM. Use the electronic service tool in order to clear all logged diag-
tween the sensor signal terminal on the harness connector for Result: The measured resistance is less than 5 Ohms.
the sensor and the sensor signal terminal on the P1
connector. Contact the DSN.
If the procedure did not correct the fault, contact the DSN.
i05945993
Speed/Timing - Test

Table 228
Diagnostic Trouble Codes for the Engine Speed/Timing Sensors

Code
190-8 Engine Speed : Abnormal Frequency, Pulse Width, The Electronic Control Module (ECM) detects the following conditions:
or Period
A loss of signal from the primary speed/timing sensor for four camshaft
revolutions.
OR
An invalid signal from the primary speed/timing sensor.
The engine speed is at least 680 rpm.
There is a valid signal from the secondary speed/timing sensor.
The warning lamp will flash. The engine will be derated. If the signal from the
secondary speed/timing sensor is also lost, the engine will shut down.
(continued)
332 UENR4504
(Table 228, contd)

Diagnostic Trouble Codes for the Engine Speed/Timing Sensors

Code
723-8 Engine Speed Sensor #2 : Abnormal Frequency, The Electronic Control Module (ECM) detects the following conditions:
Pulse Width or Period
A loss of signal from the secondary speed/timing sensor for four crankshaft
revolutions.
OR
An invalid signal from the secondary speed/timing sensor for four engine
revolutions.
The engine is running.

The loss of signal from the secondary speed/timing sensor will prevent the en-
gine from starting.
637-11 Engine Timing Sensor : Other Failure Mode The Electronic Control Module (ECM) detects the following conditions:
The outputs from the primary speed/timing sensor and the secondary speed/
timing sensor differ by more than 10 crankshaft degrees for at least four engine
revolutions.
The engine is running.
There is a valid signal from the secondary speed/timing sensor.

The engine uses two engine speed/timing sensors. • The engine will continue to run when only one
The primary speed/timing sensor is located on the sensor signal is present from either the primary
front left-hand side of the cylinder block. The primary sensor or the secondary sensor.
speed/timing sensor generates a signal by detecting
the movement of the teeth that are located on the • Loss of signal from the primary sensor and the
crankshaft timing ring. The signal that is generated by secondary sensor during operation of the engine
the speed/timing sensor is transmitted to the ECM. will cause fuel injection to be terminated and the
The ECM uses the signal from the speed/timing engine will stop.
sensor to calculate the position of the crankshaft. The
signal is also used to determine the engine speed. Pull-up Voltage
The secondary speed/timing sensor is located in the The ECM continuously outputs a pull-up voltage on
front cover. The secondary speed/timing sensor the circuit for the secondary speed/timing sensor
generates a signal that is related to the camshaft signal wire. This pull-up voltage is required for correct
position. The secondary speed/timing sensor detects sensor operation and diagnostics.
the movement of the position wheel on the front of the
camshaft. The signal that is generated by the speed/ When the sensor is disconnected, this pull-up voltage
timing sensor is transmitted to the ECM. The ECM can be measured at the harness connector for the
calculates the speed and the rotational position of the sensor.
engine by using the signal. The secondary speed/
timing sensor is required for starting purposes.
During normal operation, the secondary speed/timing
sensor is used to determine the cycle that the engine
is on. When the timing has been established, the
primary speed/timing sensor is then used to
determine the engine speed and the angular position.
The loss of signal to the primary sensor and/or the
secondary sensor will result in one of the following
faults:
UENR4504 333

Schematic diagram for the engine speed/timing sensors

View of the pin locations for the speed/timing sensors View of the pin locations for the speed/timing sensors
on the 62-pin connector on the P2 connector
(4) Secondary speed/timing sensor signal (13) Secondary speed/timing sensor 5 VDC supply
(8) Secondary speed/timing sensor ground (14) Secondary speed/timing sensor signal
(9) Primary speed/timing sensor supply (28) Secondary speed/timing sensor ground
(10) Primary speed/timing sensor return (44) Primary speed/timing sensor return
(11) Primary speed/timing sensor shield (59) Primary speed/timing sensor supply
(12) Secondary speed/timing sensor 5 VDC supply
334 UENR4504

View of the sensor locations
(1) Primary speed/timing sensor (2) Secondary speed/timing sensor

Typical example of the secondary speed/timing sensor
(1) Secondary speed/timing sensor ground (3) Secondary speed timing sensor 5 VDC
(2) Secondary speed/timing sensor signal supply
UENR4504 335
Table 229
or connector
A. Turn the keyswitch to the OFF position. Repair the damaged wire or the damaged connector.
B. Inspect the connectors for the speed/timing sensors. Refer des. Verify that the repair eliminates the fault.
to Troubleshooting, “Electrical Connectors - Inspect”.
C. Inspect the 62-pin engine interface connector. Refer to nected and/or inserted and the harness is free of corrosion, of
Troubleshooting, “Electrical Connectors - Inspect”. abrasion or of pinch points.
D. Perform a 30 N (6.7 lb) pull test on each of the wires in the Proceed to Test Step 2.
suspect sensor connector and the sensor connections at the
ECM.
D. Check that the ground connection on the ECM and the neg-
ative terminal on the battery are correctly installed.
E. Check the ground connection on the ECM for abrasions

and pinch points.
F. Check the harness for abrasion and pinch points from the
suspect sensor to the ECM.
G. Check that the suspect sensor is installed correctly. Check

that the suspect sensor is fully seated into the engine. Check
that the sensor is securely latched.
2. Check for Active Diagnostic Codes and Recently Diagnostic Result: Diagnostic code 190-8 is active or recently logged.
Logged Diagnostic Codes codes
Result: Diagnostic code 723-8 is active or recently logged.
B. Connect the electronic service tool to the diagnostic
C. Turn the keyswitch to the ON position. If the engine will Result: Diagnostic code 637-11 is active or recently logged.
start, then run the engine.
D. Use the electronic service tool in order to monitor active di-
agnostic codes or recently logged diagnostic codes.
(continued)
336 UENR4504
(Table 229, contd)

3. Measure the Signal Frequency at the Sensor Connector At least 100 Hz. Result: The measured frequency is less than 100 Hz.
A. Turn the keyswitch to the OFF position. Remove the primary speed/timing sensor. Refer to Disassem-
bly and Assembly, “Crankshaft Position Sensor - Remove and
B. Disconnect the primary speed/timing sensor. Install”.
Note: A multimeter that can measure frequency (Hz) is re- Inspect the primary speed/timing sensor for damage and/or
quired for this procedure. debris.
If the primary speed/timing sensor is free from damage and/or
C. Connect the multimeter to pin 1 and pin 2 on the sensor debris, install a new primary speed/timing sensor. Refer to Dis-
connector. assembly and Assembly, “Crankshaft Position Sensor - Re-
move and Install”.
D. Turn the keyswitch to the START position. Use the electronic service tool in order to clear all logged diag-
E. Record the frequency while the engine is cranking. If the primary speed/timing sensor is damaged and/or contami-
nated with debris, proceed to Test Step 10.
Result: The measured frequency is greater than 100 Hz.
4. Check the Engine Wiring Harness Less than 5 Result: At least one of the resistance measurements is greater
Ohms than 5 Ohms.
The fault is in the wiring between the primary speed/timing sen-
B. Disconnect the primary speed/timing sensor. Disconnect sor and the 62-pin connector.
the P2 ECM connector. Replace the faulty wiring.
C. Measure the resistance between pin 1 on the harness con- des and verify that the repair eliminates the fault.
nector for the primary speed/timing sensor and P2:59.
Result: Both resistance measurements are less than 5 Ohms.
D. Measure the resistance between pin 2 on the harness con-
nector for the primary speed/timing sensor and P2:44. Proceed to Test Step 5.
5. Check the Harness Between the Engine and the ECM Less than 5 Result: At least one of the resistance measurements is greater
Ohms than 5 Ohms.
The fault is in the harness between the 62-pin connector and
B. Disconnect the 62-pin engine interface connector. Discon- the P2 connector.
nect the P2 ECM connector. Thoroughly inspect the P2/J2 Replace the faulty wiring.
connector. Refer to Troubleshooting, “Electrical Connectors - Use the electronic service tool to clear all logged diagnostic co-
Inspect”. des and verify that the repair eliminates the fault.
C. Measure the resistance between pin 9 on the 62-pin con- Result: Both resistance measurements are less than 5 Ohms.
nector on the harness between the engine and the ECM and
P2:59. Contact the Dealer Solution Network (DSN).
D. Measure the resistance between pin 10 on the 62-pin con-

nector on the harness between the engine and the ECM and
P2:44.
(continued)
UENR4504 337
(Table 229, contd)

6. Check the Sensor Supply Voltage at the Sensor 4.9 V to 5.1 V Result: The measured voltage is not within the expected
Connector range.
B. Disconnect the connector for the secondary speed/timing Result: The measured voltage is within the expected range.
sensor.
engine.
D. Measure the voltage between pin 1 and pin 3 on the har-

ness connector for the secondary speed/timing sensor.
F. Reconnect the connector for the secondary speed/timing

sensor.
7. Check the Sensor Supply Voltage at the 62-Pin 4.9 V to 5.1 V Result: The measured voltage is within the expected range.
Connector
A. Turn the keyswitch to the OFF position. tween the sensor and the 62-pin connector.
B. Disconnect the 62-pin engine interface connector. Start the engine. Use the electronic service tool to clear all
C. Turn the keyswitch to the ON position. Do not attempt to the fault.
start the engine.
D. Measure the voltage between pin 8 and pin 12 on the 62- range.
pin connector on the harness between the engine and the
ECM. The fault is in the 5 VDC supply wire or the ground wire be-
tween the 62-pin connector and the P2 connector.
E. Turn the keyswitch to the OFF position. Replace the faulty wiring.
Start the engine. Use the electronic service tool to clear all
F. Reconnect the 62-pin engine interface connector. logged diagnostic codes and verify that the repair eliminates
the fault.
8. Check for Signal Voltage at the Sensor Connector 4.52 to 4.72 V Result: The measured voltage is within the expected range.
A. Turn the keyswitch to the OFF position. Replace the secondary speed/timing sensor. Refer to Disas-
sembly and Assembly, “Camshaft Position Sensor - Remove
B. Disconnect the connector for the secondary speed/timing and Install” for the correct procedure.
sensor. Start the engine. Use the electronic service tool to clear all
start the engine.
D. Measure the voltage between pin 1 and pin 2 on the har- range.
ness connector for the secondary speed/timing sensor.
F. Reconnect the secondary speed timing sensor.
(continued)
338 UENR4504
(Table 229, contd)

9. Check the Sensor Signal Voltage at the 62-Pin 4.52 V to 4.72 V Result: The measured voltage is within the expected range.
Connector
The fault is in the sensor signal wire between pin 2 on the sen-
A. Turn the keyswitch to the OFF position. sor connector and pin 4 on the 62-pin connector.
B. Disconnect the 62-pin engine interface connector. Start the engine. Use the electronic service tool to clear all
start the engine.
D. Measure the voltage between pin 4 and pin 8 on the 62-pin range.
connector on the harness between the engine and the ECM.
F. Reconnect the 62-pin engine interface connector.
10. Check the Sensor Signal Voltage at the ECM 4.52 to 4.72 V Result: The measured voltage is within the expected range.
A. Turn the keyswitch to the OFF position. The fault is in the sensor signal wire between pin 4 on the 62-
pin connector and P2:14.
B. Disconnect the P2 connector. Replace the faulty wiring. Use the electronic service tool to
clear all logged diagnostic codes and verify that the repair elimi-
start the engine.
D. Measure the voltage between J2:14 and J2:28 on the ECM. range.
E. Turn the keyswitch to the OFF position. Contact the DSN.
F. Reconnect the P2 connector.
(continued)
UENR4504 339
(Table 229, contd)

11. Inspect the Sensors Diagnostic code Result: A 637-11 diagnostic code is not active at this time.
A. Ensure that the speed/timing sensors are correctly seated Use the electronic service tool to clear all logged diagnostic co-
in the cylinder block and the front cover and that the retaining des and verify that the repair eliminates the fault.
bolts are tightened to the correct torque. Refer to Disassembly
and Assembly, “Crankshaft Position Sensor - Remove and In- Result: A 637-11 diagnostic code is still active at this time.
stall” or refer to Disassembly and Assembly, “Camshaft Posi-
tion Sensor - Remove and Install”. Ensure that the speed/ Proceed to Test Step 12.
timing sensors are not damaged.
B. Replace any damaged sensors. Refer to Disassembly and

Assembly, “Crankshaft Position Sensor - Remove and Install”
or refer to Disassembly and Assembly, “Camshaft Position
Sensor - Remove and Install”.
C. Use the electronic service tool to check if the 637-11 diag-

nostic code is still active.
12. Check the Crankshaft Timing Ring and the Camshaft Defects Result: Found fault with the crankshaft timing ring or the cam-
Position Wheel shaft position wheel
A. Inspect the crankshaft timing ring. Refer to Disassembly If necessary, replace the camshaft position wheel. Refer to Dis-
and Assembly, “Crankshaft Timing Ring - Remove and Install”. assembly and Assembly, “Camshaft Gear - Remove and
Install”.
B. Inspect the camshaft position wheel. Refer to Disassembly If necessary, replace the crankshaft timing ring. Refer to Disas-
and Assembly, “Camshaft Gear - Remove and Install”. sembly and Assembly, “Crankshaft Timing Ring - Remove and
Install”.
nostic codes and then verify that the repair has eliminated the
fault.
Contact the DSN.
i05946111
Switch Circuits - Test

(Engine Oil Pressure Switch)
Use this procedure to diagnose electronic faults in the

oil pressure switch circuit.
340 UENR4504
Table 230
Diagnostic Trouble Codes for the Oil Pressure Switch
100-2 Engine Oil Pressure : Erratic, Intermittent, or Incorrect When the keyswitch is in the ON position (engine not run-
ning), the oil pressure switch circuit should be closed.
This diagnostic code will be active when the Electronic Con-

trol Module (ECM) detects the following conditions:
The engine is not running.
The circuit for the oil pressure switch is open for at least 3
seconds.
The keyswitch has been switched on for at least 6 seconds.
The engine is equipped with an oil pressure switch.

While the engine is running and oil pressure is
detected, the switch will be open. When no oil
pressure is detected, the switch will be closed.
Table 231
Oil Pressure Switch States and Diagnostics Summary
Oil Pressure Switch Active Diagnostic

Engine Condition
State Code
Not running Closed Normal condition (no
oil pressure
detected)
Running Open Normal condition (oil

pressure detected)
Not running Open 100-2
Running Closed 100-17
Note: If a 100-17 diagnostic code is active, refer to

Troubleshooting, “Oil Pressure Is Low” before
returning to this procedure.

Schematic diagram for the oil pressure switch circuit
UENR4504 341

View of the pin location on the 62-pin engine interface
connector for the oil pressure switch.
(3) Oil pressure switch

View of the pin location on the P2 connector for the oil
pressure switch
(6) Engine oil pressure switch
342 UENR4504
Table 232
or connector
connector. Use the electronic service tool to clear all logged diagnostic co-
B. Thoroughly inspect the connector for the oil pressure
switch. Result: All connectors, pins, and sockets are correctly con-
C. Refer to Troubleshooting, “Electrical Connectors - Inspect”. abrasion or of pinch points.
connectors that are associated with the oil pressure switch.
E. Check the harness for abrasions and for pinch points from
the oil pressure switch back to the ECM.
2. Check for Active or Recently Logged Diagnostic Codes Diagnostic Result: A 100-17 diagnostic code is recently logged.
codes
A. Turn the keyswitch to the OFF position. This diagnostic code indicates that the oil pressure is low, but
can also be caused by a short circuit condition in the oil pres-
B. Connect the electronic service tool to the diagnostic sure switch circuit.
connector. Check for engine oil pressure problems before returning to this
procedure. refer to Troubleshooting, “Oil Pressure Is Low”.
C. Turn the keyswitch to the ON position. Do not start the If the fault is still present, proceed to Test Step 3.
engine.
D. Check for any active or recently logged diagnostic codes.
Wait at least 10 seconds for activation of the diagnostic codes. Proceed to Test Step 6.
Result: A 100-2 diagnostic code is not active. A 100-17 diag-

nostic code is not recently logged.
An intermittent 100-2 diagnostic code can be caused by turning
the keyswitch to the ON position after the engine has recently
been stopped or an intermittent fault may exist.
3. Create an Open Circuit at the Switch Connector Diagnostic Result: A 100-2 diagnostic code is active with the switch
codes disconnected.
Replace the oil pressure switch. Refer to Disassembly and As-
B. Disconnect the harness connector for the oil pressure sembly, “Engine Oil Pressure Switch - Remove and Install”.
switch. Use the electronic service tool to clear all logged diagnostic co-
engine. Result: A 100-2 diagnostic code is not active with the oil pres-
sure switch disconnected.
D. Use the electronic service tool to check for an active 100-2
diagnostic code. Wait at least 10 seconds for activation of the Reconnect the harness connector for the oil pressure switch
diagnostic code. and proceed to Test Step 4.
(continued)
UENR4504 343
(Table 232, contd)

4. Create an Open Circuit at the 62-Pin Connector Diagnostic Result: A 100-2 diagnostic code is active with the 62-pin con-
B. Disconnect the 62-pin engine interface connector. oil pressure switch.
C. Turn the keyswitch to the ON position. Do not start the en- Use the electronic service tool to clear all logged diagnostic co-
gine. Wait at least 30 seconds for activation of the diagnostic des and verify that the repair eliminates the fault.
codes.
Result: A 100-2 diagnostic code is not active with the wire
D. Use the electronic service tool to check for an active 100-2 disconnected.
diagnostic code.
Reconnect the wire that was previously removed. Proceed to
Note: Diagnostic codes for all of the engine sensors will be ac- Test Step 5.
codes and only look for a 100-2 diagnostic code.
5. Create an Open Circuit at the ECM Connector Diagnostic Result: A 100-2 diagnostic code is active with the P2 connector
codes disconnected.
A. Disconnect the P2 connector from the ECM.
B. Turn the keyswitch to the ON position. Do not attempt to P2 connector.
start the engine. Wait at least 30 seconds for activation of the Replace the faulty wiring.
diagnostic codes. Use the electronic service tool to clear all logged diagnostic co-
C. Use the electronic service tool to check for an active 100-2
diagnostic code. Result: A 100-2 diagnostic code is not active with the wire
Note: Diagnostic codes for all of the engine sensors will be ac- disconnected.
des and only look for a 100-2 diagnostic code. Contact the Dealer Solution Network (DSN).
6. Create a Short at the Switch Connector Diagnostic Result: A 100-2 diagnostic code is not active with the jumper
codes installed.
Replace the oil pressure switch. Refer to Disassembly and As-
B. Disconnect the harness connector for the oil pressure sembly, “Engine Oil Pressure Switch - Remove and Install”.
switch. Use the electronic service tool to clear all logged diagnostic co-
C. Fabricate a jumper wire and install the jumper wire between
the harness connector for the oil pressure switch and a suit- Result: A 100-2 diagnostic code is active with the jumper
able ground. installed.
D. Turn the keyswitch to the ON position. Do not start the Proceed to Test Step 7.
engine.
E. Use the electronic service tool to check for an active 100-2

diagnostic code. Wait at least 10 seconds for activation of the
diagnostic code.
(continued)
344 UENR4504
(Table 232, contd)

7. Create a Short at the 62-Pin Connector Diagnostic Result: A 100-2 diagnostic code is not active with the jumper
codes installed.
The short is in the wiring between pin 3 on the 62-pin connector
B. Disconnect the 62-pin engine interface connector. and the harness connector for the oil pressure switch.
C. Fabricate a jumper wire and install the jumper wire between Use the electronic service tool to clear all logged diagnostic co-
terminal 3 on the 62-pin connector on the harness between des and verify that the repair eliminates the fault.
the engine and the ECM and a suitable ground.
D. Turn the keyswitch to the ON position. Do not attempt to installed.
start the engine. Wait at least 30 seconds for activation of the
diagnostic codes. Reconnect the 62-pin connector. Proceed to Test Step 8.

diagnostic code.
codes and only look for a 100-2 diagnostic code.
8. Create a Short at the ECM Connector Diagnostic Result: A 100-2 diagnostic code is not active with the jumper
Codes installed.
The fault is in the wiring between the oil pressure switch and
B. Disconnect the P2 connector from the ECM. the P2 ECM connector.
C. Fabricate a jumper wire and install the jumper wire between clear all logged diagnostic codes and verify that the repair elimi-
J2:6 and a suitable ground. nates the fault.
D. Turn the keyswitch to the ON position. Do not attempt to Result: A 100-2 diagnostic code is active with the jumper
start the engine. Wait at least 30 seconds for activation of the installed.
diagnostic codes.
Contact the DSN.
diagnostic code.
des and only look for a 100-2 diagnostic code.
UENR4504 345
i05946649
Switch Circuits - Test

(Throttle Switch)
Table 233
Diagnostic Trouble Codes for the Throttle Switch Circuit
J1939
Description Notes
Code
2880-2 Engine Operator Primary Intermediate Speed Select : Erratic, In- The Electronic Control Module (ECM) detects the following
termittent, or Incorrect conditions:
The signal voltage from the throttle switch is between 0.35 V and
4.8 V.
The signal voltage from the throttle switch is not valid for any of
the available modes for at least 0.5 seconds.
Above Normal
The signal voltage from the throttle switch is above 4.8 VDC for
at least 0.5 seconds.
Below Normal
The signal voltage from the throttle switch is less than 0.35 VDC
for at least 0.5 seconds.
The throttle switch uses resistors to modify the

voltage signal from the ECM. The resistance of the
switch changes dependent on which position the
switch is in. The ECM uses the signal voltage to
determine which mode has been selected.

View of the signal voltage range for the throttle switch
346 UENR4504

Typical example of the schematic for the throttle switch

for the throttle switch
(55) Throttle switch signal
(77) Throttle switch ground
UENR4504 347
Table 234
connector found.
A. Thoroughly inspect the terminal connections on the P1/J1
B. Thoroughly inspect the connector for the throttle switch. Result: A damaged wire or damaged connector was
found.
C. Refer to Troubleshooting, “Electrical Connectors - Inspect”.
D. Perform a 30 N (6.7 lb) pull test on each of the wires in the con- Use the electronic service tool to clear all logged diag-
nectors that are associated with the throttle switch. nostic codes. Verify that the repair eliminates the fault.
switch back to the ECM.
2. Check for Active or Recently Logged Diagnostic Codes Diagnostic Trou- Result: A 2880-4 diagnostic code is active.
ble Codes

C. Turn the keyswitch to the ON position. Do not start the engine.
D. Check for active diagnostic codes with the throttle switch in each
position. Wait at least 10 seconds with the switch in each position Result: A 2880-2 diagnostic code is active.
for activation of the diagnostic codes.
3. Create an Open Circuit at the Switch Diagnostic codes Result: A 2880-3 diagnostic code is active with the
switch disconnected.
Replace the throttle switch.
B. Disconnect the throttle switch. Use the electronic service tool to clear all logged diag-
C. Turn the keyswitch to the ON position. fault.
D. Use the electronic service tool to check for an active 2880 diag- Result: A 2880-4 diagnostic code is still active with the
nostic code. Wait at least 10 seconds for activation of the diagnos- switch disconnected.
tic codes.
4. Create a Short at the Switch Connector Diagnostic codes Result: A 2880-4 diagnostic code is active with the jump-
er installed.
Replace the throttle switch.
B. Disconnect the throttle switch. Use the electronic service tool to clear all logged diag-
C. Fabricate a jumper wire and install the jumper wire between the fault.
two harness connector terminals for the throttle switch.
Result: A 2880-3 diagnostic code is still active with the
D. Turn the keyswitch to the ON position. jumper installed.
E. Use the electronic service tool to check for an active 2880 diag- Reconnect the throttle switch and proceed to Test Step 7.
nostic code. Wait at least 10 seconds for activation of the diagnos-
tic codes.
(continued)
348 UENR4504
(Table 234, contd)

5. Check the Voltage at the Switch Connector 4.9 V to 5.1 V Result: The voltage is within the expected range.
A. Turn the keyswitch to the OFF position. Replace the throttle switch.
B. Disconnect the throttle switch. nostic codes and verify that the repair eliminates the
fault.
Result: The voltage is not within the expected range.
D. Use a suitable multimeter to measure the voltage between the
signal terminal and the ground terminal at the switch connector. Proceed to Test Step 6.
Less than 5
6. Check the Wiring for High Resistance Ohms Result: At least one of the resistance measurements is
greater than 5 Ohms.
The fault is in the wiring between the switch connector
B. Disconnect the throttle switch. Disconnect the P1 connector. and the P1 connector.
Check all wiring between the throttle switch and the
C. Use a suitable multimeter to measure the resistance between ECM. Refer to the Electrical Schematic for the
the following points: application.
·P1:55 to the signal terminal at the switch connector Use the electronic service tool to clear all logged diag-
·P1:77 to the ground terminal at the switch connector nostic codes and verify that the repair eliminates the
fault.
Result: Both resistance measurements are less than 5

Ohms.
7. Check the Wiring for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is
Ohm less than 1 k Ohm.
There is a short in the wiring between the throttle switch
B. Disconnect the P1 connector from the ECM. and the P1 connector.
Check all wiring between the throttle switch and the
C. Disconnect the throttle switch. ECM. Refer to the Electrical Schematic for the
application.
D. Use a suitable multimeter to measure the resistance between Replace the faulty wiring.
the following points: Use the electronic service tool to clear all logged diag-
·P1:55 and all other terminals on the P1 connector fault.
·P1:77 and all terminals on the P1 connector
Result: All resistance measurements are greater than 1
k Ohm.
i05946079
Switch Circuits - Test Use this procedure to diagnose electronic faults in the
air filter restriction switch circuit.
(Air Filter Restriction Switch) This procedure covers the following diagnostic code:
UENR4504 349
Table 235
Diagnostic Trouble Codes for the Air Filter Restriction Switch
107-2 Engine Air Filter 1 Differential Pressure : Erratic, Inter- This code indicates a fault in the circuit for the air filter restriction switch.
The Electronic Control Module (ECM) detects the following conditions:
The signal from the air filter restriction switch indicates a restriction.
The engine is not running.
The ECM has been powered for at least 6 seconds.

Monitoring of air filter restriction while the engine is running will be dis-
abled while this code is active.
If the engine is equipped with an air filter restriction

switch, the type of switch that is installed can be
either “Normally Open” or “Normally Closed” . The
parameter for the type of switch that is installed can
be set using the electronic service tool.
Use the electronic service tool to check which type of
switch is installed in the application before continuing
with this procedure.
Ensure that the parameter is set correctly for the type
of switch that is installed in the application. Refer to
the OEM for more information.
Table 236
Diagnostic Summary for a “ Normally Open”” Air Filter Restric-
tion Switch
Active Diagnostic
Engine Condition Switch State
Code
Not running (key on) Open Normal condition
Running Open Normal Condition

(no air filter restric-
tion detected)
Not running Closed 107-2
Running Closed 107-15 or 107-16
Table 237
Diagnostic Summary for a “ Normally Closed”” Air Filter Re-
striction Switch
Active Diagnostic
Engine Condition Switch State
Code
Not running (key on) Open 107-2
Running Open 107-15 or 107-16
Not running Closed Normal condition
Running Closed Normal Condition

(no air filter restric-
tion detected)
Note: If a 107-15 or a 107-16 diagnostic code is

active, this indicates that the air inlet is restricted.
Refer to Troubleshooting, “Inlet Air Is Restricted”.
350 UENR4504

Schematic diagram for an air filter restriction switch

air filter restriction switch
(87) Air filter restriction switch
UENR4504 351
Table 238
or connector
connector. Use the electronic service tool to clear all logged diagnostic co-
B. Thoroughly inspect the connector for the air filter restriction
switch. Result: All connectors, pins, and sockets are correctly con-
C. Refer to Troubleshooting, “Electrical Connectors - Inspect”. abrasion or of pinch points.
connectors that are associated with the air filter restriction
switch.
E. Check the harness for abrasions and for pinch points from
the switch back to the ECM.
2. Check for Active or Recently Logged Diagnostic Codes Diagnostic Result: A 107-2 diagnostic code is not active.
codes
A. Turn the keyswitch to the OFF position. If the diagnostic code is recently logged, an intermittent fault
may exist.
B. Connect the electronic service tool to the diagnostic Refer to Troubleshooting, “Electrical Connectors - Inspect” in
connector. order to identify intermittent faults.
C. Turn the keyswitch to the ON position. Do not start the Result: A “Normally Open” switch is installed. A 107-2 diag-
engine. nostic code is active.
D. Use the electronic service tool to check whether a “Nor- A short circuit condition exists in the air filter restriction switch
mally Open” or “Normally Closed” air filter restriction switch circuit.
is installed in the application. Proceed to Test Step 3.
E. Check for any active or recently logged diagnostic codes. Result: A “Normally Closed” switch is installed. A 107-2 diag-
Wait at least 10 seconds for activation of the diagnostic codes. nostic code is active.
An open circuit condition exists in the air filter restriction switch

circuit.
3. Create an Open Circuit at the Switch Connector Diagnostic Result: The fault is cleared with the switch disconnected.
codes
A. Turn the keyswitch to the OFF position. Replace the air filter restriction switch.
B. Disconnect the connector from the air filter restriction des and verify that the repair eliminates the fault.
switch.
Result: The 107-2 diagnostic code is still active with the air fil-
C. Turn the keyswitch to the ON position. Do not start the ter restriction switch disconnected.
engine.
Reconnect the connector to the air filter restriction switch and
D. Use the electronic service tool to check for an active 107-2 proceed to Test Step 4.
diagnostic code.
(continued)
352 UENR4504
(Table 238, contd)

4. Check the Wiring for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is less
Ohm than 1 k Ohm
The fault is in the wiring between the air filter restriction switch
B. Disconnect the connector for the switch. Disconnect the P1 and the P1 ECM connector.
connector from the ECM. Check all wiring between the switch and the ECM. Refer to the
C. Use a suitable multimeter to measure the resistance be- Replace the faulty wiring.
tween P1:87 and all other terminals on the P1 connector. Use the electronic service tool to clear all logged diagnostic co-
Result: All resistance measurements are greater than 1 k

Ohm.
5. Create a Short at the Switch Connector Diagnostic code Result: The fault is cleared with the jumper installed.
A. Turn the keyswitch to the OFF position. Replace the air filter restriction switch.
B. Disconnect the connector from the air filter restriction des and verify that the repair eliminates the fault.
switch.
Result: A 107-2 diagnostic code is still active with the jumper
C. Fabricate a jumper wire and install the jumper wire across installed.
the two terminals on the harness connector for the switch.

diagnostic code.
(continued)
UENR4504 353
(Table 238, contd)

6. Check the Ground Wire for the Switch Diagnostic code Result: The fault is cleared with the jumper installed.
A. Turn the keyswitch to the OFF position. The fault is in the ground wire between the air filter restriction
switch and battery negative.
B. Disconnect the connector from the air filter restriction Check all wiring between the switch and the ECM. Refer to the
switch. Electrical Schematic for the application.
C. Fabricate a jumper wire. Install the jumper wire between Use the electronic service tool to clear all logged diagnostic co-
the signal terminal on the harness connector for the switch des and verify that the repair eliminates the fault.
D. Turn the keyswitch to the ON position. installed.
E. Use the electronic service tool to check for an active 107-2 Proceed to Test Step 7.
diagnostic code.
7. Check the Wiring for an Open Circuit Less than 5 Result: The measured resistance is greater than 5 Ohms.
Ohms
A. Turn the keyswitch to the OFF position. There is an open circuit or high resistance in the wiring between
the air filter restriction switch and the ECM.
B. Disconnect the connector for the switch. Disconnect the P1 Check all wiring between the switch and the ECM. Refer to the
connector from the ECM. Electrical Schematic for the application.
C. Use a suitable multimeter to measure the resistance be- Use the electronic service tool to clear all logged diagnostic co-
tween P1:87 and the signal terminal on the harness connector des and verify that the repair eliminates the fault.
for the switch.
i05946651
Valve Position - Test
354 UENR4504
Table 239
Diagnostic Trouble Codes for the Valve Position Sensors

Code
27-3 Engine Exhaust Gas Recirculation The Electronic Control Module (ECM) detects that the signal voltage from the position sensor
Valve Position : Voltage Above on the Exhaust Gas Recirculation (EGR) valve is greater than 4.8 VDC for at least 0.5
Normal seconds.
The ECM will set the valve to the default position while this code is active. The default position
is 0 percent.
27-4 Engine Exhaust Gas Recirculation The ECM detects that the signal voltage from the position sensor on the EGR valve is less
Valve Position : Voltage Below than 0.2 VDC for at least 0.35 seconds.
Normal
The ECM will set the valve to the default position while this code is active. The default position
is 0 percent.
51-3 Engine Throttle Valve 1 Position : The ECM detects the following conditions:
Voltage Above Normal
The signal voltage from the position sensor on the intake throttle valve is greater than 4.75
VDC for at least 0.5 seconds.
The intake throttle valve will move to the default position while the diagnostic code is active.
The default position is 0 percent.
51-4 Engine Throttle Valve 1 Position : The ECM detects the following conditions:
Voltage Below Normal
The signal voltage from the position sensor on the intake throttle valve is less than 0.25 VDC
for at least 0.5 seconds.
The intake throttle valve will move to the default position while the diagnostic code is active.
The default position is 0 percent.
Use this procedure in order to troubleshoot the The troubleshooting procedures for the diagnostic
position sensors for the following valves: codes of each position sensor are identical. The ECM
supplies 5 VDC to terminal “1” of the engine intake
• EGR valve throttle valve connector and to terminal “6” of the
EGR valve connector. The sensor common from the
• Engine intake throttle valve ECM connector goes to terminal “3” of the engine
intake throttle valve connector and to terminal “4” of
Each position sensor is an integral part of the the EGR valve connector. The sensor supply is
associated valve. If the following procedure indicates output short circuit protected. A short circuit to the
a fault with the position sensor, then the entire valve battery will not damage the circuit inside the ECM.
must be replaced. The signal voltage from terminal “5” of the engine
intake throttle valve and from terminal “2” of the EGR
The following background information is related valve is supplied to the appropriate terminal at the P2/
to this procedure: J2 ECM connector.
UENR4504 355

Schematic diagram for the valve position sensors

interface connector for the motorized valves for the valve position sensors.
(29) EGR valve PWM signal (8) Intake throttle valve position sensor 5 VDC supply
(30) EGR valve return (9) EGR valve position sensor 5 VDC supply
(33) EGR valve position sensor 5 VDC supply (24) EGR valve position sensor ground
(34) EGR valve position sensor signal (34) Intake throttle valve return
(35) EGR valve position sensor ground (35) EGR valve return
(37) Intake throttle valve PWM signal (37) Intake throttle valve position sensor ground
(38) Intake throttle valve return (39) EGR valve position sensor signal
(41) Intake throttle valve position sensor 5 VDC supply (49) Intake throttle valve PWM signal
(42) Intake throttle valve position sensor signal (50) EGR valve PWM signal
(43) Intake throttle valve position sensor ground (53) Engine intake throttle valve position sensor signal
356 UENR4504
Table 240
1. Verify All Active and Recently Logged Diagnostic Diagnostic Result: None of the preceding diagnostic codes are active or
Codes codes recently logged.
A. Turn the keyswitch to the ON position. Wait at least 10 sec- The fault may be intermittent. Refer to Troubleshooting, “Electri-
onds for activation of the diagnostic codes. cal Connectors - Inspect” in order to identify intermittent faults.
B. Verify if any of the diagnostic codes that are listed in Table Result: One or more of the preceding diagnostic codes are ac-
239 are active or recently logged. tive or recently logged.
2. Inspect Electrical Connectors And Wiring Damaged wire Result: A damaged wire or damaged connector was found.
or connector
ECM connectors. Use the electronic service tool to clear all logged diagnostic co-
B. Thoroughly inspect the connectors for the valves.
C. Thoroughly inspect the 62-pin connector. nected and/or inserted and the harness is free of corrosion, of
abrasion or of pinch points.
D. Refer to Troubleshooting, “Electrical Connectors - Inspect”.
ECM connector, the 62-pin engine interface connector, and
the valve connectors that are associated with the active diag-
nostic code.
F. Check the harness for abrasions and for pinch points from
the valves back to the ECM.
3. Measure the Sensor Supply Voltage at the Valve 4.9 v to 5.1 V Result: The measured voltage is not within the expected
Connector range.
B. Disconnect the suspect valve from the engine harness. Result: The measured voltage is within the expected range.
D. Measure the voltage at the harness connector for the valve

from the 5 VDC supply terminal of the position sensor to the
sensor ground terminal.
(continued)
UENR4504 357
(Table 240, contd)

4. Measure the Supply Voltage at the 62-Pin Connector 4.9 V to 5.1 V Result: The voltage is within the expected range.
A. Turn the keyswitch to the OFF position. The fault is in the 5 VDC supply wire or the ground wire be-
tween the valve connector and the 62-pin engine interface
B. Disconnect the 62-pin connector. connector.
C. Turn the keyswitch to the ON position. Use the electronic service tool to clear all logged diagnostic co-
D. Use a suitable voltmeter to measure the voltage at the 62-
pin connector. Measure the voltage between the 5 VDC supply Result: The voltage is not within the expected range.
pin and the ground pin for the suspect valve.
E. Reconnect the 62-pin connector. tween the 62-pin engine interface connector and the ECM.
5. Verify the Type of Active Diagnostic Code Diagnostic Result: An XX-4 diagnostic code is active at this time.
codes
Result: An XX-3 diagnostic code is active at this time.
6. Create an Open Circuit at the Valve Connector Diagnostic Result: An XX-3 diagnostic code is active with the valve
codes disconnected.
Reconnect the connector for the valve.
B. Disconnect the connector for the valve with the XX-4 diag- If the XX-4 diagnostic code returns, there is a short in the valve.
nostic code. Install a replacement valve. Refer to Disassembly and Assem-
bly for the correct procedure.
C. Turn the keyswitch to the ON position. Wait for at least 10 If the EGR valve is replaced, use the electronic service tool to
seconds for activation of the diagnostic codes. perform the “EGR Valve Learn Reset” .
D. Use the electronic service tool to check the “Active Diag- des and verify that the repair eliminates the fault.
nostic Code” screen. Check for an XX-3 diagnostic code.
Note: Diagnostic codes for all of the engine sensors will be ac- Result: There is still an XX-4 diagnostic code active with the
tive with the P2 connector disconnected. Ignore all other co- valve disconnected.
(continued)
358 UENR4504
(Table 240, contd)

7. Create an Open Circuit at the 62-Pin Connector Diagnostic Result: An XX-3 diagnostic code is active with the 62-pin con-
The fault is in the wiring between the valve connector and the
B. Disconnect the 62-pin connector. 62-pin engine interface connector.
C. Turn the keyswitch to the ON position. Wait for at least 10 Use the electronic service tool to clear all logged diagnostic co-
seconds for activation of the diagnostic codes. des and verify that the repair eliminates the fault.
D. Use the electronic service tool to check the “Active Diag- Result: An XX-4 diagnostic code is still active with the 62-pin
nostic Code” screen. Check for an XX-3 diagnostic code for connector disconnected.
the suspect sensor.
Note: Diagnostic codes for all of the engine sensors will be ac- Reconnect the 62-pin connector. Proceed to Test Step 8.
codes and only look for codes that relate to the suspect
sensor.
8. Create an Open Circuit at the ECM Connector Diagnostic Result: An XX-3 diagnostic code is active with the P2 connec-
Codes tor disconnected.
The fault is in the wiring for the suspect sensor between the 62-
B. Disconnect the P2 connector from the ECM. pin connector and the P2 connector.
C. Turn the keyswitch to the ON position. Wait at least 10 sec- Use the electronic service tool in order to clear all logged diag-
onds for activation of the diagnostic codes. nostic codes and then verify that the repair eliminates the fault.
Result: An XX-4 diagnostic code is still active with the P2 con-
D. Use the electronic service tool in order to monitor the “Ac- nector disconnected.
tive Diagnostic Code” screen. Check for an XX-3 diagnostic
code for the suspect sensor. Contact the Dealer Solution Network (DSN).
des and only look for codes that relate to the suspect sensor.
9. Create a Short Circuit at the Valve Connector Diagnostic Result: An XX-4 diagnostic code is active when the jumper is
codes installed.
Reconnect the connector for the suspect valve.
B. Disconnect the connector for the valve with the XX-3 diag- Turn the keyswitch to the ON position. Use the electronic serv-
nostic code. ice tool to check for active diagnostic codes.
If the XX-3 diagnostic code returns, there is an open circuit in
C. Fabricate a jumper wire that is 150 mm (6 inch) long. the valve.
Install a replacement valve. Refer to Disassembly and Assem-
D. Insert one end of the jumper wire into the terminal for the bly for the correct procedure.
valve position sensor signal on the harness connector for the If the EGR valve is replaced, use the electronic service tool to
suspect valve. Insert the other end of the jumper into the termi- perform the “EGR Valve Learn Reset” .
nal for the sensor ground on the harness connector for the Use the electronic service tool to clear all logged diagnostic co-
suspect valve. des and verify that the repair eliminates the fault.
E. Turn the keyswitch to the ON position. Wait at least 10 sec- Result: An XX-3 diagnostic code remains active when the
onds for activation of the diagnostic codes. jumper is installed.
F. Access the “Active Diagnostic Codes” screen on the elec- Proceed to Test Step 10.
code for the suspect sensor.
(continued)
UENR4504 359
(Table 240, contd)

10. Create a Short Circuit at the 62-Pin Connector Diagnostic Result: An XX-4 diagnostic code is active when the jumper is
codes installed.
The fault is in the wiring between the valve connector and the
B. Disconnect the 62-pin connector. 62-pin engine interface connector.
the jumper between the suspect sensor signal terminal and des and verify that the repair eliminates the fault.
the sensor ground terminal on the 62-pin connector on the
harness between the engine and the ECM. Result: The XX-3 is still active with the jumper installed.
D. Turn the keyswitch to the ON position. Do not attempt to Reconnect the 62-pin connector. Proceed to Test Step 11.
diagnostic codes.
E. Access the “Active Diagnostic Codes” screen on the elec-

code.
diagnostic codes and only look for codes that relate to the sus-
pect sensor.
11. Create a Short Circuit at the ECM Connector Diagnostic Result: An XX-4 diagnostic code is active with the jumper wire
codes installed.
The fault is in the wiring for the suspect sensor between the 62-
B. Disconnect the P2 connector from the ECM. pin connector and the P2 connector.
the jumper between the suspect sensor signal pin and the des and verify that the repair eliminates the fault.
sensor ground pin on the J2 connector.
Result: The XX-3 diagnostic code is still active with the jumper
D. Turn the keyswitch to the ON position. Do not attempt to wire installed.
diagnostic codes. Contact the DSN.
E. Use the electronic service tool to check for an active XX-4

diagnostic code for the suspect sensor.
des and only look for codes that relate to the suspect sensor.

wire.
i05946674 The Water In Fuel (WIF) sensor is a normally open

sensor. During normal operation, there will be no
Water in Fuel - Test signal sent from the WIF sensor to the ECM. If water
is detected in the fuel, the sensor will send a signal to
the ECM. If the signal remains constant for 60
seconds, a 97-15 diagnostic code will become active.
For a 97-15 diagnostic code, refer to Troubleshooting, This diagnostic code can also be caused by a short in
“Fuel Contains Water” before returning to this the WIF sensor circuit.
procedure.
Water-in-Fuel Sensor Operation
360 UENR4504

Schematic diagram for the WIF sensor circuit

Typical view of the pin location on the P1 connector
for the WIF sensor
(30) WIF sensor signal
UENR4504 361
Table 241
or connector
A. Turn the keyswitch to the OFF position. Repair the damaged wire or the damaged connector.
B. Thoroughly inspect the connector for the WIF sensor and des. Verify that the repair eliminates the fault.
the P1/J1 ECM connector. Refer to Troubleshooting, “Electri-
cal Connectors - Inspect”. Result: All connectors, pins, and sockets are correctly con-
C. Perform a 30 N (10 lb) pull test on each of the wires that abrasion or of pinch points.
are associated with the WIF sensor.
D. Check the harness for abrasions, for pinch points, and for
corrosion.
2. Check for Active Diagnostic Codes Diagnostic Result: A 97-15 diagnostic code is active.
codes
A. Connect the electronic service tool to the diagnostic Ensure that there is no water present in the fuel before continu-
connector. ing with this procedure. Refer to Troubleshooting, “Fuel Con-
tains Water”.
B. Turn the keyswitch to the ON position. Proceed to Test Step 3.
C. Wait for at least 1 minute. Result: A 97-15 diagnostic code is not active at this time.
If the WIF sensor is not operating correctly, proceed to Test
D. Monitor the active diagnostic code screen on the electronic Step 5.
service tool. Check and record any active diagnostic codes.
3. Disconnect the WIF Sensor Diagnostic Result: The code disappears with the sensor disconnected.
codes
A. Turn the keyswitch to the OFF position. Replace the WIF sensor. Use the electronic service tool to clear
all logged diagnostic codes and verify that the repair eliminates
B. Disconnect the WIF sensor from the harness. the fault.
C. Turn the keyswitch to the ON position. Wait for at least 1 Result: A 97-15 diagnostic code is still active with the sensor
minute. disconnected.
D. Use the electronic service tool to check for an active 97-15 Reconnect the sensor and proceed to Test Step 4.
diagnostic code.
4. Check the Sensor Signal Wire for a Short Circuit Greater than 1 k Result: At least one of the resistance measurements is less
Ohm than 1 k Ohm.
The fault is in the wiring between the WIF sensor and the P1
B. Disconnect the WIF sensor connector. Disconnect the P1 ECM connector.
connector from the ECM. Check all wiring between the WIF sensor and the ECM. Refer
to the Electrical Schematic for the application.
C. Use a suitable multimeter to check the resistance between Replace the faulty wiring.
P1:30 and all other terminals on the P1 connector. Use the electronic service tool to clear all logged diagnostic co-
Result: Each resistance measurement is greater than 1 k

Ohm.
(continued)
362 UENR4504
(Table 241, contd)

5. Check that the Sensor is Receiving the Correct Voltage Greater than 11 Result: The measured voltage is less than 11 V.
V
A. Turn the keyswitch to the OFF position. The fault is in the switched battery supply wiring to pin 3 on the
WIF sensor connector.
B. Disconnect the WIF sensor from the harness. Check all battery supply wiring to the WIF sensor. Refer to the
C. Turn the keyswitch to the ON position. Replace the faulty wiring.
D. Measure the voltage between terminal 3 on the harness des and verify that the repair eliminates the fault.
connector for the WIF sensor and a suitable ground.
Result: The measured voltage is at least 11 V.
6. Check the WIF sensor Ground Wire Greater than 11 Result: The measured voltage is less than 11 V.
V
A. Turn the keyswitch to the OFF position. The fault is the wiring between terminal 2 on the WIF sensor
connector and battery negative.
B. Disconnect the WIF sensor from the harness. Check all wiring between the WIF sensor and battery negative.
C. Turn the keyswitch to the ON position. Use the electronic service tool to clear all logged diagnostic co-
D. Measure the voltage between terminal 2 and terminal 3 on
the harness connector for the WIF sensor. Result: The measured voltage is at least 11 V.
7. Create a Short Circuit at the WIF Sensor Connector Diagnostic Result: A 97-15 diagnostic code is active with the jumper
codes installed.
Replace the WIF sensor.
B. Disconnect the WIF sensor from the harness. Use the electronic service tool to clear all logged diagnostic co-
C. Fabricate a jumper and install the jumper wire between ter-
minal 1 and terminal 2 on the harness connector for the WIF Result: A 97-15 diagnostic code is not active with the jumper
sensor. installed.
D. Turn the keyswitch to the ON position. Wait for at least 1 Proceed to Test Step 8.
minute.

diagnostic code.
8. Check the Sensor Signal Wire for an Open Circuit Less than 5 Result: The measured resistance is greater than 5 Ohms.
Ohms
A. Turn the keyswitch to the OFF position. The fault is in the wiring between the WIF sensor and the P1
connector.
B. Disconnect the WIF sensor. Disconnect the P1 connector Check all wiring between the WIF sensor and the ECM. Refer
from the ECM. to the Electrical Schematic for the application.
C. Use a suitable multimeter to measure the resistance be- Use the electronic service tool to clear all logged diagnostic co-
tween terminal 1 on the harness connector for the WIF sensor des and verify that the repair eliminates the fault.
and P1:30.
Contact the DSN.
UENR4504 363
Index Section
Index
A Probable Causes ......................................... 70
Recommended Actions................................ 70
Acceleration Is Poor or Throttle Response
Is Poor............................................................ 54
Probable Causes ......................................... 54 D
Alternator Is Noisy ........................................... 57 DEF Concentration Is Incorrect ....................... 71
Probable Causes ......................................... 57 DEF Does Not Purge....................................... 73
Recommended Actions................................ 57 DEF Injector - Test ......................................... 189
Alternator Problem (Charging Problem and/ DEF Line Heater - Test .................................. 193
or Noisy Operation)........................................ 59 DEF Module Does Not Respond ..................... 75
Probable Causes ......................................... 59 DEF Pressure Does Not Respond................... 76
Recommended Actions................................ 59 DEF Pressure Is High ...................................... 80
DEF Pressure Is Low....................................... 82
DEF Pump - Test ........................................... 199
B DEF Pump Pressure Sensor - Test................ 205
DEF Return Valve - Test ................................ 209
Battery Problem............................................... 60
DEF Tank Level Is Low .................................... 86
Probable Causes ......................................... 60
DEF Tank Sensor - Test................................. 213
DEF Tank Temperature Is High........................ 88
DEF Tank Temperature Is Low ........................ 92
C Diagnostic Functional Tests........................... 184
Diagnostic Trouble Codes ............................. 175
CAN Data Link - Test ..................................... 184
Coolant Contains Oil........................................ 61
Probable Causes ......................................... 61 E
ECM Does Not Communicate with Other
Coolant Level Is Low ....................................... 63
Modules ......................................................... 95
Coolant Temperature Is High........................... 63
Probable Causes ......................................... 95
Probable Causes ......................................... 63
ECM Harness Connector Terminals ................ 31
Coolant Temperature Is Low............................ 66
ECM Memory - Test ....................................... 218
Probable Causes ......................................... 66
Electrical Connector - Inspect........................ 221
Electrical Power Supply - Test ....................... 224
Crankcase Breather Ejects Oil ........................ 67
Electronic Service Tool Does Not
Probable Causes ......................................... 68
Communicate................................................. 95
Probable Causes ......................................... 95
Customer Specified Parameters...................... 41
Aftertreatment Configuration........................ 44
Electronic Service Tools .................................. 12
Configurable Inputs...................................... 42
Optional Service Tools ................................. 12
Configurable Outputs................................... 43
Perkins Electronic Service Tool................... 13
Engine Idle Shutdown.................................. 41
Required Service Tools ................................ 12
J1939 Continuous Fault Handling................ 44
Electronic Troubleshooting ................................ 5
Miscellaneous .............................................. 42
Engine Cranks but Does Not Start................... 97
PTO and Throttle Lock Parameters ............. 41
Probable Causes ......................................... 97
Speed Control .............................................. 41
Throttle Configuration .................................. 44
Engine Does Not Crank................................. 102
Customer Specified Parameters Table ............ 45
Probable Causes ....................................... 102
Customer Specified Parameters Worksheet ... 49
Recommended Repairs ............................. 102
Cylinder Is Noisy.............................................. 70
364 UENR4504
Index Section
Engine Has Early Wear ................................. 104 Probable causes ........................................ 140
Probable Causes ....................................... 104 Recommended Actions.............................. 140
Recommended Actions.............................. 104
Engine Has Mechanical Noise (Knock) ......... 106
Probable Causes ....................................... 106 G
Recommended Actions.............................. 106 Glossary ............................................................ 9
Engine Misfires, Runs Rough or Is Unstable Glow Plug Starting Aid - Test ......................... 228
..................................................................... 109
Probable Causes ....................................... 109
Recommended Actions.............................. 109 I
Engine Overspeeds........................................112 Idle Validation - Test....................................... 234
Engine Shutdown Occurs Intermittently .........112 Important Safety Information ............................. 2
Probable Causes ........................................113 Indicator Lamp - Test ..................................... 241
Recommended Actions...............................113 Indicator Lamps ............................................... 14
Engine Speed Does Not Change ...................114 Color of Lamps............................................. 15
Probable Causes ........................................114 Functions of the Lamps................................ 14
Recommended Repairs ..............................114 Indicator Lamps ........................................... 14
Engine Stalls at Low RPM ..............................115 Operation of the Indicator Lamps................. 16
Probable Causes ........................................115 Injector Code - Calibrate.................................. 34
Recommended Actions...............................115 Injector Data Incorrect - Test.......................... 245
Engine Top Speed Is Not Obtained ................117 Injector Solenoid - Test .................................. 248
Probable Causes ........................................117 Inlet Air Is Restricted...................................... 141
Recommended Actions...............................117 Inlet Air Temperature Is High ......................... 142
Engine Vibration Is Excessive ....................... 120 Probable Causes ....................................... 142
Recommended Actions.............................. 120 Intake Manifold Air Pressure Is High ............. 143
Engine Wiring Information ............................... 23 Probable Causes ....................................... 143
Harness Wire Identification.......................... 23 Recommended Actions.............................. 144
Schematic Diagrams.................................... 24 Intake Manifold Air Pressure Is Low .............. 144
Exhaust Has Excessive Black Smoke........... 122 Probable Causes ....................................... 145
Recommended Actions.............................. 122 Intake Manifold Air Temperature Is High........ 146
Exhaust Has Excessive White Smoke .......... 125 Probable Causes ....................................... 146
Recommended Actions.............................. 125
Exhaust System Contains Oil ........................ 128
Probable Causes ....................................... 128 M
Mode Selection - Test .................................... 255
F Mode Switch Setup.......................................... 35
Engine High Idle Speed (RPM).................... 35
Flash Programming ......................................... 34 Engine Operating Mode #1 High Idle Droop
Flash Programming a Flash File .................. 34 Percentage................................................. 36
Fuel Consumption Is Excessive .................... 130 Engine Operating Mode #1 High Idle Speed
Probable Causes ....................................... 130 ................................................................... 36
Recommended Actions.............................. 130 Engine Operating Mode #1 Throttle #1 Droop
Fuel Contains Water ...................................... 133 Percentage................................................. 36
Recommended Actions.............................. 133 Engine Operating Mode #1 Throttle #2 Droop
Fuel Rail Pressure Problem........................... 134 Percentage................................................. 36
Probable Causes ....................................... 136 Engine Operating Mode #1 TSC1 Droop
Recommended Actions.............................. 136 Percentage................................................. 36
Fuel Temperature Is High .............................. 140
UENR4504 365
Index Section
Engine Operating Mode #2 High Idle Droop Measuring Fuel Dilution ............................. 157
Percentage................................................. 36 Probable Causes ....................................... 158
Engine Operating Mode #2 High Idle Speed Recommended Actions.............................. 158
................................................................... 36 Oil Pressure Is Low........................................ 159
Engine Operating Mode #2 Throttle #1 Droop Probable Causes ....................................... 160
Percentage................................................. 36 Recommended Actions.............................. 160
Engine Operating Mode #2 Throttle #2 Droop
Percentage................................................. 36
Engine Operating Mode #2 TSC1 Droop P
Percentage................................................. 36 Power Is Intermittently Low or Power Cutout
Engine Operating Mode #3 High Idle Droop Is Intermittent ............................................... 162
Percentage................................................. 37 Probable Causes ....................................... 162
Engine Operating Mode #3 High Idle Speed Recommended Actions.............................. 163
................................................................... 37 Power Take-Off - Test .................................... 268
Engine Operating Mode #3 Throttle #1 Droop Programming Parameters ............................... 34
Percentage................................................. 37
Engine Operating Mode #3 Throttle #2 Droop
Percentage................................................. 37 R
Engine Operating Mode #3 TSC1 Droop Relay - Test (ECM Main Relay) ..................... 278
Percentage................................................. 37 Relay - Test (SCR Relay)............................... 282
High Idle Droop Percentage......................... 35 Relay - Test (Start Relay)............................... 273
Throttle #1 Droop Percentage...................... 35 Replacing the ECM.......................................... 17
Throttle #2 Droop Percentage...................... 35
TSC1 Droop Percentage.............................. 36
Motorized Valve - Test ................................... 258 S
Multiposition Switch Setup............................... 39 SCR Catalyst Has Incorrect Inlet
Mode Select Enable/Disable........................ 39 Temperature................................................. 165
Multi State Input Switch Enable Status ........ 39 SCR Warning System Problem ..................... 166
Throttle Lock Maximum Engine Speed........ 39 Associated Codes...................................... 167
Throttle Position #1 Engine Speed .............. 40 Inducement for low-level DEF.................... 170
Throttle Position #2 Engine Speed .............. 40 Operator Level Inducement ....................... 166
Throttle Position #3 Engine Speed .............. 40 Self-Diagnostics............................................... 18
Throttle Position #4 Engine Speed .............. 40 Sensor (Data Link Type) - Test (Ammonia
Sensor) ........................................................ 288
N Sensor Signal (Analog, Active) - Test ............ 303
Sensor Signal (Analog, Active) - Test
NOx Conversion Is Low................................. 149 (Exhaust Gas Pressure Sensor).................. 297
NOx Sensor - Test ......................................... 264 Sensor Signal (Analog, Passive) - Test ......... 309
NRS Mass Flow Rate Problem...................... 151 Sensor Supply - Test...................................... 292
Probable Causes ....................................... 151 Sensors and Electrical Connectors ................. 19
Recommended Actions.............................. 151 854F-E34TA Engine.................................... 19
Clean Emissions Module (CEM).................. 22
Service Tool Features...................................... 31
O
Active Diagnostic Codes.............................. 31
Oil Consumption Is Excessive ....................... 153 Calibrations.................................................. 32
Probable Causes ....................................... 153 Component Replacement Resets................ 32
Recommended Actions.............................. 153 Diagnostic Tests........................................... 31
Oil Contains Coolant...................................... 155 Logged Diagnostic Codes............................ 31
Probable Causes ....................................... 155 Override Parameters.................................... 31
Recommended Actions.............................. 155 Solenoid Valve - Test ..................................... 319
Oil Contains Fuel ........................................... 157
366 UENR4504
Index Section
Solenoid Valve - Test (Coolant Diverter Recommended Actions.............................. 174

Valve)........................................................... 316 Valve Position - Test ...................................... 353
Speed Control (Analog) - Test ....................... 326
Speed/Timing - Test....................................... 331
Switch Circuits - Test (Air Filter Restriction W
Switch) ......................................................... 348 Water in Fuel - Test........................................ 359
Switch Circuits - Test (Engine Oil Pressure Welding Precaution ........................................... 5
Switch) ......................................................... 339
Switch Circuits - Test (Throttle Switch) .......... 345
Symptom Troubleshooting............................... 54
System Configuration Parameters................... 53
ECM Identification Parameters .................... 53
Engine Rating Information ........................... 53
System Overview............................................... 5
Block Diagram................................................ 7
Electronic Control Circuit Diagram................. 6
Other ECM Functions for Performance.......... 9
Programmable Parameters............................ 9
System Operation .......................................... 8
T
Table of Contents............................................... 3
Throttle Setup .................................................. 37
Throttle #1 Idle Validation Maximum On
Threshold ................................................... 38
Throttle #1 Idle Validation Minimum Off
Threshold ................................................... 38
Throttle #1 Idle Validation Switch Enable
Status ......................................................... 38
Throttle #1 Initial Lower Position.................. 38
Throttle #1 Lower Diagnostic Limit............... 38
Throttle #1 Upper Diagnostic Limit............... 38
Throttle #2 Idle Validation Maximum On
Threshold ................................................... 39
Throttle #2 Idle Validation Minimum Off
Threshold ................................................... 39
Throttle #2 Idle Validation Switch Enable
Status ......................................................... 39
Throttle #2 Initial Lower Position.................. 38
Throttle #2 Initial Upper Position.................. 38
Throttle #2 Lower Diagnostic Limit............... 39
Throttle #2 Upper Diagnostic Limit............... 39
Throttle Enable Status ................................. 37
Troubleshooting Section.................................... 5
Troubleshooting with a Diagnostic Code ....... 175
V
Valve Lash Is Excessive ................................ 174
Probable Causes ....................................... 174
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UENR4504

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents DEF Pressure Is High ................... .................. 80

DEF Line Heater - Test ................. ................ 193

Index............................... .............................. 363

Correct welding procedures are necessary in order to

The following information provides a general

System Operation • Coolant temperature sensor

Customer Parameters and Engine Speed

Refer to Troubleshooting, “Configuration Parameters” Diagnostic Trouble Code – A diagnostic trouble

sensor. The reference voltage is used by the sensor

Throttle Position Sensor – The throttle position T400079 Extraction Tool

Table 2 (Table 3, contd)

• Programmable parameter settings

• Programming of flash file

• Copy configuration function for Electronic Control

• Graphs (real time)

1. Turn the keyswitch to the OFF position.

Module (ECM), refer to the diagnostic procedure

Connecting the Electronic Service Tool Indicator Lamps

• “Wait to start” lamp

• “Emissions system failure” lamp

• “DEF quality” lamp

Functions of the Lamps

1. Turn the keyswitch to the OFF position.

Wait to Start Lamp

Low Oil Pressure Lamp

Emissions System Failure Lamp

Low DEF Lamp

DEF Quality Lamp

Operation of the Indicator Lamps

After a short time, the engine will

i05857949 Note: Ensure that the ECM is receiving power and

2. From the menu bar go to the following menu • ECM Replacement

Sensors and Electrical Connectors

Clean Emissions Module (CEM)

Engine Wiring Information

Harness Wire Identification

Wiring from the Engine to the Electronic Control Module (ECM)

Wiring for the Application

ECM Harness Connector • Diagnostic Tests

Glow Plug Starting Aid Override

DEF Pressure Line Heater Override

DEF Backflow and Suction Line Heater

Active Diagnostic Codes

Logged Diagnostic Codes

Cylinder Cutout Select the “Calibrations” tab.

DEF Dosing System Verification Test SCR Catalyst Replacement Reset

Calibrations EGR Cooler Replacement Reset

Engine Emissions Operator Inducement

i04035800 e. When the correct flash file is selected, press

i04215913 7. Start the engine and check for proper operation.

Flash Programming a Flash File i05867872

Exchanging electronic unit injectors can help

Mode Switch Setup

The Mode Switches can be used to change the

Engine High Idle Speed (RPM)

• Injector Trim Calibration Throttle #1 Droop Percentage

8. Click on the “OK” button.

Exchanging Electronic Unit Injectors Minimum Maximum

TSC1 Droop Percentage Table 14

Engine Operating Mode #3 High i05920711