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| Illustration 1 | g06177323 |
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Not all component quantities are shown. Aftertreatment system may contain two CEM packages. (1) Exhaust inlet (2) Inlet Nitrogen Oxide (NOx) sensor (3) Diesel Exhaust Fluid (DEF) injector (4) Catalyst brick (5) Outlet NOx sensor (6) Exhaust out (7) DEF supply line (8) Coolant return to engine line (9) DEF pump (10) Coolant supply from engine line (11) Coolant diverter valve (12) DEF tank (13) Coolant supply connector (14) Suction connector (15) Backflow connector (16) Coolant return connector (17) DEF suction line (18) DEF backflow line (19) Dosing Control Unit (DCU) (20) Aftertreatment Electronic Control Module (ECM) | |
The purpose of Diesel Exhaust Fluid (DEF) is to create a Selective Catalytic Reduction (SCR) process to take place in the exhaust system to reduce Nitrogen Oxides (NOx).
When the engine is keyed on but not running, DEF is not being injected into the system. When the engine is running, the DEF may be too cold or frozen to be injected. When the ambient or tank temperatures are cold enough, the DEF control unit (DCU) opens the coolant diverter valve to allow engine coolant to flow through the DEF tank to warm the system. The DCU also activates the heater circuits in the lines and pump to prevent DEF from freezing in the lines and pump. The time it takes to thaw the system depends on the tank temperature. Since the system always starts with empty lines, the pump activates to fill the lines with fluid before DEF injection begins.
Once the system is thawed and primed, the DEF will be injected into the exhaust system when the DEF tank and SCR temperatures are warm enough. If the system does not heat up after duration of time, a diagnostic code will become active.
Note: Typical usage for DEF is 1-3% of diesel fluid. The DEF tank should be refilled at the same time as the fuel tank.
The DEF system has three operation modes:
1. DEF Priming Mode
Since the system always starts with empty lines, the pump activates to fill the lines with fluid before DEF injection begins. Priming will start when engine speed is greater than 450 rpm, DEF tank temp is greater than
2. DEF Injection Mode
Once the system is primed, the DEF will be injected when SCR inlet temperature is greater than
3. DEF Purge Mode
When a DEF-related fault code becomes active or the engine is keyed OFF, the DCU enters purge mode. The system is designed to purge all DEF back to the DEF tank to prevent the DEF from freezing in the pump and lines. The DEF injector opens and the DEF Reverting valve in the DEF pump reverses the flow of the DEF inside the pump. This reversal removes the DEF from the pressure line and pumps the DEF back to tank through the suction line. The purge takes approximately 2 minutes to remove DEF from the lines and pump. DO NOT turn off the battery disconnect switch during the purge process. If the purge process does not complete and the temperature of the DEF drops below
NOx Monitoring
There are four NOx sensors supplied with the engine. Two NOx sensors are installed in the exhaust inlet from the turbocharger (CEM inlet). The other NOx sensors are installed in the exhaust pipe of the application (CEM out).
The amount of DEF needed is based on NOx production. The engine produces NOx as the engine operates at a specific target to meet emission requirements. The engine out NOx sensor measures the amount and communicates that value to the DCU. The tailpipe out NOx sensor monitors the NOx level out of the catalyst and communicates that value to the DCU. Based on the engine out and the tail pipe out NOx sensor values, the flow rate of DEF will adjust to meet the NOx allowed per regulations.
NOx Sensors
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| Illustration 2 | g03364155 |
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(21) Electrical connector
(22) Sensor electronic control unit (23) Cable (black for engine out, gray for CEM out) (24) Sensing unit | |
The NOx sensor contains a sensing element, a harness, and an electronic control unit. The sensing element is composed of two chambers and a heater. The first chamber measures the amount of oxygen and the second chamber measure the amount of NOx and Ammonia (NH3). Using electrochemistry, a ceramic material attracts ions at approximately
Note: For information on handling the NOx sensors, refer to Special Instruction, REHS8151.
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| Illustration 3 | g06177354 |
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The DEF pumps are on the front side of the Pump Electronic Tank Unit (PETU). (25) Aftertreatment #1 DEF Pump #1 (26) Aftertreatment #1 DEF Pump #2 (27) Aftertreatment #2 DEF Pump #1 (28) Aftertreatment #2 DEF Pump #2 (29) Coolant diverter valve for Aftertreatment #1 DEF Pump #1 (30) Coolant diverter valve for Aftertreatment #1 DEF Pump #2 (31) Coolant diverter valve for Aftertreatment #2 DEF Pump #1 (32) Coolant diverter valve for Aftertreatment #2 DEF Pump #2 (33) Aftertreatment #1 DEF Pump #1 header (34) Aftertreatment #1 DEF Pump #2 header (35) Aftertreatment #2 DEF Pump #1 header (36) Aftertreatment #2 DEF Pump #2 header (37) Aftertreatment #1 DEF Pump #1 backflow valve (38) Aftertreatment #1 DEF Pump #2 backflow valve (39) Aftertreatment #2 DEF Pump #1 backflow valve (40) Aftertreatment #2 DEF Pump #2 backflow valve (41) Aftertreatment #1 DEF Pump #1 electrical connection for DEF header (42) Aftertreatment #1 DEF Pump #2 electrical connection for DEF header (43) Aftertreatment #2 DEF Pump #1 electrical connection for DEF header (44) Aftertreatment #2 DEF Pump #2 electrical connection for DEF header | |
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| Illustration 4 | g06177378 |
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(45) Aftertreatment #1 DEF Pump #1 Heater Line
(46) Aftertreatment #1 DEF Pump #2 Heater Line (47) Aftertreatment #2 DEF Pump #1 Heater Line (48) Aftertreatment #2 DEF Pump #2 Heater Line (49) Aftertreatment #1 DEF Pump #1 Backflow Line (50) Aftertreatment #1 DEF Pump #2 Backflow Line (51) Aftertreatment #2 DEF Pump #1 Backflow Line (52) Aftertreatment #2 DEF Pump #2 Backflow Line (53) Aftertreatment #1 DEF Pump #1 Suction Line (54) Aftertreatment #1 DEF Pump #2 Suction Line (55) Aftertreatment #2 DEF Pump #1 Suction Line (56) Aftertreatment #2 DEF Pump #2 Suction Line (57) Voltage Limiting Protection Module (VLPM) (58) Line Heater Relay #1 (59) Line Heater Relay #2 (60) Line Heater Relay #3 (61) Line Heater Relay #4 | |
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| Illustration 5 | g06177435 |
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(62) Aftertreatment #1 DCU #1
(63) Aftertreatment #1 DCU #2 (64) Aftertreatment #2 DCU #1 (65) Aftertreatment #2 DCU #2 (66) Selective Catalyst Reduction System ECM (67) Main Power Relay | |
The Pump Electronics Tank Unit (PETU) consists of the following components:
Coolant Diverter Valves
Controls coolant flow to the tank and DEF pump for DEF tank and DEF pump heating.
Power Relays
There are 5 total power relays contained in the PETU. The main power relay is for the entire PETU. The other 4 power relays are for the 4 DEF line heaters.
Diesel Exhaust Fluid Control Unit (DCU)
The DCU controls all the functions related to the pumping and injection of DEF into the exhaust stream.
Heated Lines
The heated lines are electrically heated lines that will turn on any time ambient temperature and DEF tank temperature are below a threshold. The heated lines will also stay heated during operation in cooler ambient conditions to prevent any freezing during operation.
Voltage Line Protection Module (VLPM)
Protects all electrical components from voltage spikes.
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| Illustration 6 | g06177445 |
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(1) 100 micron screen
(2) Inlet (3) Coolant inlet (4) Coolant outlet (5) Backflow (6) Outlet (7) DEF filter | |
The pump supplies filtered DEF fluid to the DEF injector. The pump consists of an inlet port (2) which is the suction side of the pump that draws DEF from the DEF tank. The pump then pressurizes the fluid up to
Once the engine is shut down, the pump will start to go into a purge mode. The DEF Injector will open and the reverting valve within the pump will reverse the flow of the pump and purge the pump and pressure line. This reversed flow will route any remaining DEF fluid back to the tank through the inlet port.
The DEF inlet connector has a 100 micron screen (1) to filter any debris that may come in from the DEF tank.
The main DEF filter (7), filters the DEF coming into the pump before going out the back flow and outlet lines. The DEF filter is serviceable and has a 4,500-hour maintenance interval. Refer to Operation and Maintenance Manual for the correct procedure to replace the DEF filter.
Engine coolant is routed through the pump during cold-weather operation.
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| Illustration 7 | g06184636 |
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(1) DEF tank header filter (32 micron) (If equipped)
(2) DEF level sensor (float) (3) Coolant tubes (4) DEF tank temperature sensor (integrated with DEF level sensor, not shown) (5) DEF tank header filter (100 micron) | |
The DEF tank header is located in the DEF tank. The tank header consists of several parts and performs the following functions:
DEF Level Sensor
There is a tank level sensor to measure the amount of usable DEF in the tank. The level sensor includes a flotation device that contains a magnet. As the fluid level changes, the float slides along a shaft that a series of reed switches and resistors. There are multiple reed switches for different heights of the tank. The magnetic float closes the passive reed switch and completes the circuit of resistors giving a different resistance output. The DCU then interprets the resistance to a tank level and changes the DEF gauge. The tank level sensor will send a signal to the DCU to signal that the level of DEF is low. The engine may derate and a fault code will become active if the level of DEF is below a critical level.
DEF Pickup Tube
The DEF is pulled from the bottom of the tank through a screen.
DEF Tank Header Screen
At the end of the DEF Pickup tube is a 100 micron screen to filter debris from entering the system. The screen is a serviceable part and has a 6,000 hour service maintenance interval.
DEF Tank Header Filter
A 32 micron filter wraps around the coolant tubes to filter debris from entering the pickup and backflow circuits. The DEF manifold filter is serviceable and has a 6,000 hour service maintenance interval.
Coolant Tubes
The coolant supplied by the engine will flow through the tubes when the coolant diverter valve opens. Coolant runs along the pickup tube to the bottom of the tank and then spirals around the level sensor. The heat from the coolant will thaw any frozen DEF in the tank or header. The heat will also prevent the DEF from freezing around the pickup tube.
DEF Backflow Tube
The pump has a backflow circuit to return DEF back to the tank. The backflow tube returns the DEF to the top of the tank.
DEF Tank Temperature Sensor
At the bottom of the tank header near the DEF tank header screen is a tank temperature sensor. This sensor monitors the temperature of the DEF in the tank. This temperature is used to determine when to turn on the coolant diverter valve.
DEF Quality Sensor (If Equipped)
At the bottom of the tank header next to the DEF tank header filter is the DEF quality sensor. The DEF quality sensor uses an optical Near Infra-Red (NIR) technology that takes measurements of urea concentration by measuring the chemical properties of the DEF solution. Based on these chemical properties and fluid temperature, the sensor is able to detect urea concentration with accuracy of up to 2 percent. If the sensor detects the quality of DEF is not within specifications, a fault code will trip indicating the DEF concentration is not correct. The engine may derate.
Later engines have a DEF quality sensor installed. There is a configuration parameter in the electronic service tool called "Aftertreatment #1 DEF Quality Sensor Installation Status" that must be programmed to "Installed". The parameter is factory password protected. The DEF tank header with the DEF quality sensor is a data link type sensor. The temperature sensor and level sensor are also data link type sensors on DEF tank headers with the quality sensor.
On earlier engines, the DEF tank header does not have a DEF quality sensor installed. The DEF tank header only contains a temperature sensor and level sensor which are analog type sensors. The configuration parameter in the electronic service tool called "Aftertreatment #1 DEF Quality Sensor Installation Status" must be programmed to "Not installed".
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| Illustration 8 | g06177453 |
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(1) Coolant return port
(2) DEF Supply line (3) Electrical Connector (4) Coolant supply port | |
The DEF injector is mounted to the Clean Emissions Module (CEM). The DEF injector is a valve that injects DEF as a fine spray into the exhaust stream as an atomized mist. The spray pattern being conical for good mixing with the exhaust is critical.
The tip of the injector, that is located in the exhaust flow, is cooled by coolant that flows through an internal coolant passage from the engine coolant supply. The injector can become damaged when exposed to high temperatures so keeping the injector cooled is important. The coolant flow, and the DEF injection process, provides the cooling capability needed to protect the injector.
High temperatures at engine shutdown can exceed the hardware limit of the DEF injector and damage the injector tip. To protect the injector from high temperature at engine shutdown, the "Delayed Engine Shutdown" (DES) strategy will run for a time after the engine start switch key is turned to the OFF position. This strategy allows the engine to continue running to prevent high exhaust temperatures from damaging the DEF injector at engine shutdown. Once the exhaust temperatures are below a threshold, the injector is cooled and the engine will shut down.
Some applications may use an Injector Coolant Tank (ICT) instead of DES to protect the DEF injector. The ICT provides a reservoir of coolant above the injector which keeps the injector cooled so that high exhaust temperatures at engine shutdown will not damage injector. Coolant boils at the injector and vapor travels up into ICT while liquid coolant from ICT backfills coolant lost to boiling. Energy lost to boiling helps to maintain injector temperatures below hardware limits.
Note: The DEF injector must be replaced, not cleaned. If the DEF injector is removed from the CEM, the previous gasket must be replaced with a new gasket.
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| Illustration 9 | g06059218 |
The DEF backflow valve is installed in between the DEF pump backflow line and the DEF header to help maintain proper pressure in the DEF system while injection is taking place. The DEF backflow valve is controlled by a PWM signal. The DEF backflow valve is a normally closed valve that is commanded to open.
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| Illustration 10 | g06177457 |
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(1) Aftertreatment #1 Pump #1 Coolant Diverter Valve
(2) Aftertreatment #1 Pump #2 Coolant Diverter Valve (3) Aftertreatment #2 Pump #1 Coolant Diverter Valve (4) Aftertreatment #2 Pump #2 Coolant Diverter Valve (5) Aftertreatment #1 Pump #1 Coolant Lines (6) Aftertreatment #1 Pump #2 Coolant Lines (7) Aftertreatment #2 Pump #1 Coolant Lines (8) Aftertreatment #2 Pump #2 Coolant Lines | |
Since DEF freezes at
Note: If DEF has not been removed from the lines and pump during cold-weather operation, the DEF will expand as the fluid freezes and damage the lines and pump. The purge process will take 2 minutes of run time and must complete. The purge process may occur during Delayed Engine Shutdown.DO NOT turn off the battery disconnect switch during the purge process. Do not turn off the battery power disconnect switch until battery disconnect switch indicator lamp has turned off. If the purge process does not complete, a diagnostic code will become active.
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| Illustration 11 | g06184637 |
| (1) Flow direction indicator | |
The coolant diverter valve is a normally closed valve. The valve is a unidirectional flow valve. The system is used for warming the DEF tank before dosing will occur. Warming the system is achieved by taking warm coolant from the engine and routing the coolant through the tank and DEF pump. The coolant diverter valve will open when the tank temperature needs to be increased. Once the DEF tank temp is warm enough, the system will start dosing.
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| Illustration 12 | g03037439 |
Even though the system has been purged of DEF there are small quantities of DEF that can be left behind. The DEF supply line, suction, and the back flow line are heated to thaw any remaining DEF in the lines. The heated lines will prevent restrictions in the pump and injector once the system begins to dose.
- Thermoplastic core tube with fabric reinforcement
- Stainless steel heating wire
- Extruded thermoplastic jacket
- Heat/abrasion shield
Inducement is defined as something that helps bring about an action or a desired result. The purpose of inducements is to prompt the operator to repair or perform maintenance on the emissions control system.
Inducement strategies are control actions required by EPA/ARB Tier 4 final and European Union (EU) Stage IV regulations to ensure prompt correction of various failures in the engine NOx emissions control system. They require actions to limit engine performance and define required indications such as visual alarms including lamps and messages, as well as audible alarms, while the control actions are imposed. The times for lights, derates, and alarms will vary between EPA and EU.
The inducements are initiated by the engine ECM. Inducements include derates and forced idle down or shutdown. When the engine derates, the rpm and torque are reduced.
Note: Operator Inducement Service Mode Override can be used to override the inducements so the equipment has full power. Factory passwords are required to activate this override.
Programmable parameters to select different Inducements options
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| Illustration 13 | g06246019 |
- Engine Emissions Operator Inducement Regulation Configuration
Engine Emissions Operator Inducement Regulation Configuration
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| Illustration 14 | g06246004 |
This programmable parameter will define the emissions regulation that the engine will follow in the event an inducement becomes active. The location of the engine must be considered before selecting this parameter.
The "Environmental Protection Agency (EPA)" can be used in the United States (except California which should be set to "Worldwide"). Once the "EPA" configuration is selected, the unit cannot go back to "Worldwide". If used outside of this region the engine will not be emissions-compliant.
The "Worldwide" configuration may be used in any region of the world and will be emissions-compliant. In general "Worldwide" configuration is more strict than the "EPA" or "EU" configurations.
The "European Union" may only be selected if the engine will operate in Europe. Once the "European Union" configuration is selected, the unit cannot go back to "Worldwide". If used outside of this region the engine will not be emissions-compliant. Only a select number of industrial engines will be allowed to select "European Union" configuration.
Safe Harbor Mode (EPA and Worldwide)
Safe Harbor Mode (EPA and Worldwide) is a 20 minute engine run time period that the engine can be operated with full power after reaching a level 3 inducement. Once in level 3 inducement, the operator can perform a key cycle and the engine will enter Safe Harbor Mode. The safe harbor mode can be used to move the machine to a location where the machine can be serviced. If 20 minutes of engine running time has passed and the fault has not been corrected, the engine will reach final inducement with derates until the fault has been fixed. Safe Harbor Mode can only be implemented once. Safe Harbor Mode is not allowed for DEF level inducements with Worldwide configuration.
Safe Harbor Mode (European Union)
Safe Harbor Mode (European Union) is a 30 minute engine run time period that the engine can be operated with full power after reaching a level 3 inducement. Once in level 3 inducement, the operator can perform a key cycle and the engine will enter Safe Harbor Mode. The safe harbor mode can be used to move the machine to a location where the machine can be serviced. If 30 minutes of engine running time has passed and the fault has not been corrected, the engine will reach final inducement with derates until the fault has been fixed. Safe Harbor Mode can only be implemented up to three times.
Engine Emissions Operator Inducement Service Mode Override
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| Illustration 15 | g03365844 |
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| Illustration 16 | g03365848 |
Engine Emissions Operator Inducement Service Mode Override allows a technician to service inducement-related faults on a machine while having full engine operation and no derate effects. This mode is initiated through a connection with Cat ET. This mode requires a factory password to activate. Engine Emissions Operator Inducement Service Mode Override can be entered as many times as necessary and does not have a time limit. However, if Cat ET loses connection, the Override will automatically turn off. The Cat ET "Engine Emissions Operator Inducement Service Mode" is located in the "Diagnostic Tests", "System Troubleshooting Section" of the engine ECM.
Service Tests Which Override Inducements
There are several service tests which will be allowed to run while inducements are active. Service tests diagnose and fix the issue that led to inducement without the use of factory passwords. While these tests can always be run on machines, not all industrial applications will be able to run service tests while inducements are active. In those cases, the Engine Emissions Operator Inducement Service Mode Override with factory passwords will need to be used.
Service Test that Override Inducements:
- Aftertreatment System Functional Test
Inducement Strategy for DEF Level (EPA and Worldwide)
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| Illustration 17 | g06149319 |
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(55) DEF Level Gauge: This gauge shows the amount of DEF in the DEF tank.
(56) DEF Level Gauge Amber lamp: This amber lamp indicates that the DEF level is low. (57) Check Engine Lamp (CEL): This lamp activates for all engine and aftertreatment faults that affect the engine. (58) Emissions Malfunction Indicator Lamp (EMIL): This lamp activates for all emissions faults that trigger inducement strategy. (59) Action Lamp: For machine engines only, this lamp indicates a Level 2 or Level 3 fault is active. (60) Red Stop Lamp: For industrial engines only, this lamp indicates that a Level 3 fault is active. Symbol may vary. (61) Audible Alarm: For Machines, the alarm sounds when a Level 3 fault is active. | |
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| Illustration 18 | g03523436 |
If the DEF level falls below 20%, the DEF level gauge amber lamp will illuminate. To avoid inducements, turn the key to the OFF position and add DEF to the DEF tank.
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| Illustration 19 | g03523619 |
If the DEF level falls below 18%, the engine will be in level 1 inducement. A 1761-17 or E954 (1) Aftertreatment #1 Diesel Exhaust Fluid Tank Level : Low - least severe (1) diagnostic code will become active. The check engine lamp (CEL) and emissions malfunction indicator lamp (EMIL) will illuminate solid. The DEF level gauge amber lamp will continue to illuminate.
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| Illustration 20 | g03523621 |
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The action lamp will not illuminate for industrial applications. | |
If the DEF level is below 12.5%, the engine will be in level 2 inducement. A 1761-18 or E954 (2) Aftertreatment #1 Diesel Exhaust Fluid Tank Level : Low - moderate severity (2) diagnostic code will become active. The DEF level gauge amber lamp, CEL, and EMIL will remain lit. For machines, the CEL and EMIL will remain solid. For industrial applications, the CEL and EMIL will begin to flash slowly. For machines only, the action lamp will illuminate and flash.
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| Illustration 21 | g03523622 |
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Industrial applications, will use the STOP lamp and not an action lamp. There is no audible alarm for industrial application. | |
If the ECM is configured to "Reduced Performance" and the DEF tank level falls below 4.5% or the DEF pump loses prime below 6.5%, the engine will be in a level 3 final inducement with 50% derate. If the ECM is configured to "Reduced Time" and the DEF level is 6.5% or below, the engine will be in a level 3 final inducement with 50% derate. When in level 3 inducement, a 1761 -1 or E954 (3) Aftertreatment #1 Diesel Exhaust Fluid Tank Level : Low - most severe (3) diagnostic code will become active. For machines only, an audible alarm will begin to sound 20 seconds prior to the level 3 inducement. The DEF level gauge amber lamp, CEL, and EMIL will remain lit. For machines, the CEL and EMIL will remain solid and the action lamp will continue to flash. For industrial applications, the CEL and EMIL will flash at a faster rate and a red stop lamp will illuminate solid. The engine will have a 100% derate and be limited to 1000 rpm or low idle, whichever is greater. If the final inducement action in Cat ET is set to "Idle Down", then engine will continue to idle at derated condition. If set to "Shutdown", engine will shut down after 5 minutes. The engine may be restarted, but will only run for 5 minutes at derated condition before shutting down again. This action will continue until the issue is resolved.
Note: Turn the key to the OFF position and add DEF to the DEF tank to reset the DEF level inducement.
Inducement Strategy (EPA and Worldwide)
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| Illustration 22 | g03523624 |
The CEL and EMIL will illuminate solid for an SCR system fault. When in level 1 inducement, a 5246 -15 or E1389 (1) Aftertreatment SCR Operator Inducement Severity (1) diagnostic code will become active. Repeat occurrences will result in a level 1 inducement for a shorter period.
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| Illustration 23 | g03523637 |
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The action lamp will not illuminate for industrial applications. | |
If a fault condition exists for the entire duration of inducement level 1, the strategy advances to inducement level 2. When in level 2 inducement a 5246 -16 or E1389 (2) Aftertreatment SCR Operator Inducement Severity (2) diagnostic code will become active. The CEL and EMIL will remain lit. For machines, the CEL and EMIL will remain solid. For industrial applications, the CEL and EMIL will begin to flash slowly. For machines only, the action lamp will illuminate and flash. Repeat occurrences will result in a level 2 inducement for a shorter period.
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| Illustration 24 | g03523639 |
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Industrial applications, will use the STOP lamp and not an action lamp. There is no audible alarm for industrial application. | |
If a fault condition exists for the entire duration of inducement level 2, the strategy advances to inducement level 3. When in level 3 inducement a 5246 -0 or E1389 (3) Aftertreatment SCR Operator Inducement Severity (3) diagnostic code will become active. For machines only, an audible alarm will begin to sound 20 seconds prior to the level 3 inducement. For machines, the CEL and EMIL will remain solid and the action lamp will continue to flash. For industrial applications the CEL and EMIL will flash at a faster rate and a red stop lamp will illuminate solid.
The engine will have a 50% derate and be limited to 1000 rpm or low idle, whichever is greater. If the final inducement action in Cat ET is set to "Idle Down", then engine will continue to idle at derated condition. If set to "Shutdown", engine will shut down after 5 minutes. A key cycle will allow safe harbor mode to kick in. Safe harbor is only allowed once. After safe harbor, the engine will be in level 3 final inducement. If set to "Shutdown", the engine may be restarted, but will only run for 5 minutes at derated condition before shutting down again. This action will continue until the issue is resolved.
Note: Contact your Cat dealer for repairs if a fault occurs.
Inducement Strategy for DEF Level (European Union)
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| Illustration 25 | g06149319 |
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(55) DEF Level Gauge: This gauge shows the amount of DEF in the DEF tank.
(56) DEF Level Gauge Amber lamp: This amber lamp indicates that the DEF level is low. (57) Check Engine Lamp (CEL): This lamp activates for all engine and aftertreatment faults that affect the engine. (58) Emissions Malfunction Indicator Lamp (EMIL): This lamp activates for all emissions faults that trigger inducement strategy. (59) Action Lamp: For machine engines only, this lamp indicates a Level 2 or Level 3 fault is active. (60) Red Stop Lamp: For industrial engines only, this lamp indicates that a Level 3 fault is active. Symbol may vary. (61) Audible Alarm: For Machines, the alarm sounds when a Level 3 fault is active. | |
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| Illustration 26 | g03523436 |
If the DEF level falls below 20%, the DEF level gauge amber lamp will illuminate. To avoid inducements, turn the key to the OFF position and add DEF to the DEF tank.
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| Illustration 27 | g03523619 |
If the DEF level falls below 13.5%, the engine will be in level 1 inducement. A 1761-17 or E954 (1) Aftertreatment #1 Diesel Exhaust Fluid Tank Level : Low - least severe (1) diagnostic code will become active. The CEL and EMIL will illuminate solid. The DEF level gauge amber lamp will remain lit.
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| Illustration 28 | g03534876 |
When the ECM is configured to "Reduced Performance" and the DEF level is below 1%, the engine will be in level 2 inducement. A 1761-18 or E954 (2) Aftertreatment #1 Diesel Exhaust Fluid Tank Level : Low - moderate severity (2) diagnostic code will become active. The CEL and EMIL will illuminate and flash slowly. The DEF level gauge amber lamp will remain lit. The engine will have a 50% derate. When the DEF tank has been emptied of all DEF, the engine will have a 100% derate and be limited to 1000 rpm or low idle, whichever is greater. No further inducement action will occur for "Reduced Performance" configuration. Safe Harbor Mode is allowed for 3 key cycles.
When ECM is configured to "Reduced Time" and the DEF level is below 7.5%, a 1761-18 or E954 (2) Aftertreatment #1 Diesel Exhaust Fluid Tank Level: Low - moderate severity (2) diagnostic code will become active. The CEL and EMIL will illuminate and flash slowly. The DEF level gauge amber lamp will remain lit.
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| Illustration 29 | g03523637 |
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Industrial applications will use the STOP lamp and not an action lamp | |
If the ECM is configured to "Reduced Time" and the DEF level is 0%, a 1761 -1 or E954 (3) Aftertreatment #1 Diesel Exhaust Fluid Tank Level : Low - most severe (3) diagnostic code will become active. The CEL and EMIL will illuminate and flash at a fast rate. An action lamp or red stop lamp will illuminate solid. The DEF level gauge amber lamp will remain lit. The engine will have a 100% derate and be limited to 1000 rpm or low idle, whichever is greater. If the final inducement action in Cat ET is set to "Idle Down", then engine will continue to idle at derated condition. If set to "Shutdown", engine will shut down after 5 minutes. Safe Harbor Mode is allowed for 3 key cycles. After Safe Harbor Mode is completed, the engine will return to idle or shut down. If in shutdown configuration, the engine may be restarted, but will only run for 5 minutes at derated condition before shutting down again. This action will continue until the issue is resolved.
Note: Turn the key to the OFF position and add DEF to the DEF tank to reset the DEF level inducement.
Inducement Strategy (European Union)
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| Illustration 30 | g03523624 |
The CEL and EMIL will illuminate solid for an SCR system fault. If the fault is a result of poor DEF quality or SCR system fault, a level 1 inducement will occur for a duration of 10 hours. If the fault is the result of SCR system tampering, a level 1 inducement will occur for 36 hours. When in level 1 inducement, a 5246 - 15 or E1389 (1) Aftertreatment SCR Operator Inducement Severity (1) diagnostic code will become active.
The CEL and EMIL will illuminate solid for a fault resulting from poor DEF quality, SCR system tampering, or a SCR system fault. If the fault is a result of poor DEF quality or SCR system fault, a level 1 inducement will occur for a duration of 5 hours. If the fault is the result of SCR system tampering, a level 1 inducement will occur for 18 hours. When in level 1 inducement, a 5246 - 15 or E1389 (1) Aftertreatment SCR Operator Inducement Severity (1) diagnostic code will become active.
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| Illustration 31 | g03523624 |
If a fault condition exists for the entire duration of inducement level 1, the strategy advances to inducement level 2. When in level 2 inducement a 5246 -16 or E1389 (2) Aftertreatment SCR Operator Inducement Severity (2) diagnostic code will become active. The CEL and EMIL will flash slowly. For poor DEF quality and SCR system faults the duration for a level 2 inducement is 10 hours for the first occurrence. Repeat occurrence will result in level 2 inducement for 2 hours. For SCR system tampering the duration for a level 2 inducement is 64 hours for the first occurrence. Repeat occurrence will result in level 2 inducement for 5 hours.
The engine will have a 75% derate. If the fault is not corrected before the inducement duration ends, the engine will become 100% derated and be limited to 1000 rpm or low idle, whichever is greater. No further inducements will occur for "Reduced Performance" configuration. Safe Harbor Mode is allowed for 3 key cycles.
If a fault condition exists for the entire duration of inducement level 1, the strategy advances to inducement level 2. When in level 2 inducement a 5246 -16 or E1389 (2) Aftertreatment SCR Operator Inducement Severity (2) diagnostic code will become active. The CEL and EMIL will flash slowly. For poor DEF quality and SCR system faults the duration for a level 2 inducement is 5 hours for the first occurrence. Repeat occurrence will result in level 2 inducement for 1 hour. For SCR system tampering, the duration for a level 2 inducement is 18 hours for the first occurrence. Repeat occurrence will result in level 2 inducement for 1 hour 48 minutes.
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| Illustration 32 | g03523637 |
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Industrial applications will use the STOP lamp and not an action lamp | |
If configured to "Reduced Time" and a fault condition exists for the entire duration of inducement level 2, the strategy advances to inducement level 3. When in level 3 inducement a 5246 -0 or E1389 (3) Aftertreatment SCR Operator Inducement Severity (3) diagnostic code will become active. The CEL and EMIL will flash at a fast rate. An action lamp or red stop lamp will also illuminate solid.
The engine will have a 100% derate and be limited to 1000 rpm or low idle, whichever is greater. If the final inducement action in Cat ET is set to "Idle Down", then engine will continue to idle at derated condition. If set to "Shutdown", engine will shut down after 5 minutes. A key cycle will allow safe harbor mode to kick in. Safe harbor is allowed up to three times. After safe harbor, the engine will be in level 3 final inducement. If set to "Shutdown", the engine may be restarted, but will only run for 5 minutes at derated condition before shutting down again. This action will continue until the issue is resolved.
Note: Contact your Cat dealer for repairs if a fault occurs.