TIP-EXTRA-DUTY 4755492 - Caterpillar

DEF Dosing System Accuracy TestThis 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".Navigate to the following screens in order to access the "DEF Dosing System Accuracy Test":
Diagnostics
Diagnostic Tests
Illustration 1 g03725285
Schematic diagram for the DEF injector circuit
Illustration 2 g03725312
View of the pin locations on the J2 ECM connector for the DEF injector
(3) DEF injector return
(18) DEF injector supply
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Check the fuses.
B. Inspect the J2/P2 ECM connector.
C. Inspect the connector for the DEF injector.
D. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM connector and the DEF injector.
E. Check all of the wiring associated with the DEF injector for abrasions and pinch points.
Damaged wire or connector
Result: A damaged wire or damaged connector was not found.
Proceed to Test Step 2.
Result: A damaged wire or damaged connector was found.
Repair: Repair the damaged wire or the damaged connector.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
2. Check for Active Diagnostic Codes
A. Establish communication between the electronic service tool and the ECM. If necessary, refer to Troubleshooting, "Electronic Service Tools".
B. Use the electronic service tool to check for active diagnostic codes.
Diagnostic Trouble Codes
Result: A 5394-6 diagnostic code is recently logged.
Proceed to Test Step 3.
Result: A 5394-5 diagnostic code is active or recently logged.
Proceed to Test Step 4.
Result: A 5394-3 diagnostic code is active or recently logged.
Proceed to Test Step 5.
Result: A 5394-4 diagnostic code is active or recently logged.
Proceed to Test Step 6.
3. Create an Open Circuit at the DEF Injector Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the DEF injector.
C. Turn the keyswitch to the ON position.
D. Use the electronic service tool to check for active 5394-5 diagnostic codes.
E. Turn the keyswitch to the OFF position.
Diagnostic codes
Result: A 5394-5 diagnostic code is not active with the DEF injector disconnected.
The fault is in the wiring between the DEF injector and the P2 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: A 5394-5 diagnostic code is active with the DEF injector disconnected.
Repair: Install a replacement DEF injector. Refer to Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install".
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
4. Create a Short Circuit at the DEF Injector Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the harness connector from DEF injector.
C. Fabricate a jumper wire