C3.4B Engines Caterpillar


DEF Tank Sensor - Test

Usage:

CCS7 4B2


Table 1
Diagnostic Trouble Codes for the DEF Tank Sensor 
J1939 Code  Code Description  Comments 
1761-7  Aftertreatment 1 Diesel Exhaust Fluid Tank Level : Not Responding Properly  The Electronic Control Module (ECM) detects an invalid signal from the Diesel Exhaust Fluid (DEF) tank level sensor for at least 5 seconds. 
1761-19  Aftertreatment #1 DEF Tank Level : Data Error  The ECM detects a loss of signal from the DEF tank level sensor for at least one second.
The battery voltage is at least 10 V.
The warning lamp will come on. 
3031-7  Aftertreatment #1 DEF Tank Temperature : Not Responding Properly  The ECM detects an invalid signal from the DEF tank temperature sensor for at least 5 seconds. 
3031-12  Aftertreatment #1 DEF Tank Temperature : Failure  The ECM detects an error message from the DEF tank temperature sensor for at least one second.
The battery voltage is at least 10 V.
The warning lamp will come on. 
3519-3  Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : Voltage Above Normal  The ECM detects a short circuit to battery voltage in the DEF temperature sensor circuit for at least 2 seconds.
The battery voltage is at least 10 V.
The warning lamp will come on. 
3519-4  Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : Voltage Below Normal  The ECM detects a short circuit to ground in the DEF temperature sensor circuit for at least 2 seconds.
The battery voltage is at least 10 V.
The warning lamp will come on. 
3520-4  Aftertreatment 1 Diesel Exhaust Fluid Properties : Voltage Below Normal  The ECM detects a short circuit to battery voltage in the DEF quality sensor circuit for at least 2 seconds.
The battery voltage is at least 10 V.
The warning lamp will come on. 
3520-12  Aftertreatment 1 Diesel Exhaust Fluid Properties : Failure  The ECM detects an error message from the DEF quality sensor for at least 2 seconds.
The battery voltage is at least 10 V.
The warning lamp will come on. 
3521-19  Aftertreatment #1 DEF Property : Data Error  The ECM detects a loss of signal from the DEF tank sensor unit for at least one second.
The battery voltage is at least 10 V.
The warning lamp will come on. 
Follow the troubleshooting procedure in order to identify the root cause of the problem. 


Illustration 1g03721809
Schematic diagram for the DEF tank header unit
Not all connectors are shown. Refer to the Electrical Schematic for the application.


Illustration 2g03721884
View of the pin locations on the P1 connector for the DEF tank header unit.
(23) CAN 2 +
(45) CAN 2 -


Illustration 3g03722336
View of the connector for the DEF tank header unit
(1) CAN C -
(2) CAN C +
(3) Ground
(4) Battery +

Table 2
Troubleshooting Test Steps  Values  Results 

1. Inspect Electrical Connectors and Wiring

A. Check the fuses.

B. Inspect the P1/J1 ECM connectors.

C. Inspect the connector for the DEF tank header unit.

D. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM connector and the connector for the DEF tank header unit.

E. Check all of the wiring associated with the DEF tank header unit for abrasions and pinch points.
 

Damaged wire or connector 

Result: A damaged wire or damaged connector was not found. The fuses are OK

Proceed to Test Step 2.

Result: A damaged wire or damaged connector was found. A fuse is blown.

Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses.
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
 

2. Check for Active or Recently Logged Diagnostic Codes

A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools"


B. Look for active or logged diagnostic codes.
 

Diagnostic Trouble Codes 

Result: One or more of the diagnostic codes listed in Table 1 is active.

Proceed to Test Step 3.

Result: There is an active diagnostic code relating to the CAN data link.

Repair: Refer to Troubleshooting, "CAN Data Link - Test" before returning to this procedure.

Result: One or more of the diagnostic codes listed in Table 1 is recently logged.

Repair: There may be an intermittent fault. Refer to Troubleshooting, "Electrical Connector - Inspect" in order to identify intermittent faults.
 

3. Check the Power Supply to the Auxiliary Main Relay

A. Turn the keyswitch to the OFF position.

B. Disconnect the auxiliary main relay.

C. Turn the keyswitch to the ON position.

D. Use a multimeter to measure the voltage between terminal 30 on the harness connector for the auxiliary main relay and a suitable ground.

E. Turn the keyswitch to the OFF position.
 

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 auxiliary main relay and battery (+).

Repair: Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Result: The measured voltage is within the expected range.

Proceed to Test Step 4.
 

4. Check the Power Supply from the ECM Main Relay

A. Turn the keyswitch to the OFF position.

B. Disconnect the auxiliary main relay.

C. Use a multimeter to measure the voltage between terminal 86 on auxiliary main relay and a suitable ground.
 

10 V to 14 V 

Result: The measured voltage is not within the expected range.

Proceed to Test Step 5.

Result: The measured voltage is within the expected range.

Proceed to Test Step 6.
 

5. Check the Wiring Between the Auxiliary Main Relay and the ECM Main Relay

A. Turn the keyswitch to the OFF position.

B. Disconnect the auxiliary main relay.

C. Disconnect the ECM main relay.

D. Use a multimeter to measure the resistance between terminal 86 on the harness connector for the auxiliary main relay and terminal 87 on the harness connector for the ECM main relay.
 
Less than 5 Ohms 
Result: The measured resistance is greater than 5 Ohms.
The fault is in the wiring between the auxiliary main relay and the ECM main relay.

Repair: Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Result: The measured resistance is less than 5 Ohms.

Repair: There may be a fault in the circuit for the ECM main relay.
Refer to Troubleshooting, "Relay - Test (ECM Main Relay)" in order to troubleshoot this circuit.
 

6. Check the Ground Connections for the Auxiliary Main Relay and the DEF Tank Header Unit

A. Turn the keyswitch to the OFF position.

B. Disconnect the auxiliary main relay.

C. Disconnect the harness connector for the DEF tank header unit.

D. Turn the keyswitch to the ON position.

E. Use a multimeter to measure the voltage between the following points:

· Terminal 30 and terminal 85 on the harness connector for the relay
· Terminal 30 on the harness connector for the relay and terminal 3 on the harness connector for the DEF tank header unit

F. Turn the keyswitch to the OFF position.
 

10 V to 14 V 

Result: At least one of the voltage measurements is not within the expected range.

Repair: Check the ground connections. If necessary, replace the ground wiring for the auxiliary main relay and the DEF tank header unit.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Result: Both voltage measurements are within the expected range.

Reconnect the auxiliary main relay. Proceed to Test Step 7.
 

7. Check the Power Supply to the DEF Tank Header Unit

A. Turn the keyswitch to the OFF position.

B. Disconnect the harness connector for the DEF tank header unit.

C. Turn the keyswitch to the ON position.

D. Use a multimeter to measure the voltage between terminal 4 on the harness connector for the DEF tank header unit and a suitable ground.

E. Turn the keyswitch to the OFF position. 

10 V to 14 V 

Result: The measured voltage is not within the expected range.

Proceed to Test Step 8.

Result: The measured voltage is within the expected range.

Proceed to Test Step 9.
 

8. Check the Wiring Between the DEF Tank Header Unit and the Auxiliary Main Relay

A. Turn the keyswitch to the OFF position.

B. Disconnect the harness connector for the DEF tank header unit.

C. Disconnect the auxiliary main relay.

D. Use a multimeter to measure the resistance between terminal 4 on the harness connector for the DEF tank header unit and terminal 87 on the harness connector for the auxiliary main relay.
 

Less than 5 Ohms 

Result: The measured resistance is greater than 5 Ohms.

Repair: Check the fuse. If the fuse is blown there may be a short in the wiring.
If the fuse is OK, there is an open circuit in the wiring.
Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Result: The measured resistance is less than 5 Ohms.

Repair: Install a replacement auxiliary main relay.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
 

9. Check the CAN Data Link Wiring for the DEF Tank Header Unit

A. Turn the keyswitch to the OFF position.

B. Disconnect the harness connector for the DEF tank header unit.

C. Disconnect the P1 connector from the ECM.

D. Use a multimeter to measure the resistance between the following points:

· Terminal 1 on the harness connector for the DEF tank header unit and P1:45
· Terminal 2 on the harness connector for the DEF tank header unit and P1:23
 

Less than 5 Ohms 

Result: At least one of the resistance measurements is greater than 5 Ohms.
The fault is in the wiring between the DEF tank header unit and the P1 ECM connector.

Repair: Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.

Result: Both resistance measurements are less than 5 Ohms.

Repair: Install a replacement DEF tank header unit.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. 
If this procedure did not correct the fault, contact the Dealer Solution Network (DSN). 

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