Regeneration & Common Fault Codes Cheat Sheet

Passive regeneration requires no operator interaction:

Requires a minimum DOC inlet temperature of 250°C or 480°F
Machine performs as normal (No Dosing)
Issues: None
Active regeneration, fully automatic requires no operator interaction:
Requires 3 to 4 bars of restriction and ¼ tank of fuel
Prompts operator with option to cancel incase flammables are present
Machine performs as normal (Requires Fuel Dosing)
Issues: Must remain in a running condition
Operator should not perform any action or park machine
Desorb request after accumulating 90 minutes of idle time:
Requires operator to idle machine and lower lock lever or set parking brake.
Requires 0 to 7 bars of restriction and ¼ tank of fuel.
Requires 7 to 10 minutes to perform.
Action Code L01, Request for Desorb, machine has accumulated 90 minutes of idle time.
Action Code L03, Request for Desorb, after machine accumulates 120 minutes of idle time.
Any Active or Manual Stationary regeneration will reset idle time back to zero minutes.
Issues: Machine must be in a parked condition
Request operator to perform a Manual Stationary Regeneration causing confusion.
120 minutes of idle time results in Action Level L03 which De-rates engine 15%
When denied produces Fault code A1UON3 after 90 minutes
When denied produces Fault code A1UON4 after 120 minutes
Manual Stationary Regeneration:
Preformed by operator.
Requires 4 to 7 bars of restriction and ¼ tank of fuel.
Issues: Machine must be in a parked position
Cannot be performed when specific DPF fault codes are active.
Manual Stationary Regeneration for Service:
Preformed by service personnel.
Requires 1 to 7 bars of restriction and ¼ tank of fuel.
Required to clear some active fault codes
Issues: Machine must be in a parked position
Cannot be performed when specific DPF fault codes are active
May require Insite to perform
Insite Manual Stationary Regeneration:
Preformed by service personal.
Requires 0 to 7 bars of restriction.
Cannot be performed if certain DPF fault codes are active
Cannot be performed if monitor shows 8 bars of restriction
Must be used to clear specific active DPF fault codes
Issues: Machine cannot be operated
Cannot perform with 8 bars of restriction, Action Level L04,
Must stall machine for up to 10 continuous minutes to reduce to 7 bars of restriction
 Causes for Excessive Regenerations:
1. Dirty or faulty Mass Air Flow sensor. 2. Faulty turbo or low boost
3. Faulty Boost Pressure sensor or intake temperature sensor 4. Plugged air filter
5. Air to Air Cooler is dirty, plugged, or lacks air flow 6. Cracked Air to Air Cooler
7. Damaged or leaking boost hoses. 8. Slow Fan Speed
9. Faulty injectors, causes dirt, water and injector overheat. 10. Faulty ECM
11. Leaking doser valve, on 125 and 140 engines only.

Note: If the level or restriction shown in the monitor panel and the level call out in the failure code do not
match you have one of three issues.
1. Differential pressure sensor tube is plugged and this usually occurs on the DPF inlet side.
2. The differential pressure sensor is faulty 3. The Engine Controller is faulty.

Common Fault Codes on Tier 4i Engines / Action Level L04 is Machine Down
Operator Action
Fault Description and causes
Repairable Code De-rate Bars
A1U0N3 Request for Desorb, 90m of idle time, 7 ~10 min. to complete Yes L01 NO 0~3
A1U0N4 Request for Desorb, 120m of idle time, 7~10 min. to complete Yes L03 Yes 15% 0~3
CA1117 Perform regeneration for service" Controller cannot store data NO L04 Yes 15% NA
CA1691 Efficiency (catalytic action) of KDOC is degraded. Low DOC Temps Yes L01 Yes 15% NA
CA2637 KDOC face plugging / Requires Insite plus Manual Regeneration Yes L01 Yes 15% NA
Request for Manual Regeneration, takes 40 minutes / 3 Hr for fault to
CA2639 NO 4~5
auto-reset Yes L01
CA1921 KDPF Soot Load High Error 1 Regeneration, 40~60m, may take 2 times Yes L03 Yes 15% 6~7
CA1921 CA2777 Automatic Regeneration Disabled (View in Insite only)
4 ~7
+ 2777 Go to diagnostic test / 02 / Select Enable No L03 Yes 15%
KDPF Soot Load High Error 2-Regeneration disabled-select DPF Yes 75%
CA1922 8
service & regenerate No L04
CA1922 CA2777 Automatic Regeneration Disabled (View in Insite only)
8
+ 2777 Go to diagnostic test screen 02 / Select Enable No L04 Yes 75%
CA131 Throttle sensor high error / Cause by turning throttle dial past Hi-idle stop Yes L03 Yes 15% NA
CA132 Throttle sensor low error / Cause by turning throttle dial past Idle stop Yes L03 Yes 15% NA
CA428 Water in Fuel Sensor / High error (Filters?) Yes L01 No NA
CA452 Rail pressure sensor low error (Usually Filters?) Yes L03 Yes 15% NA
CA555 Crankcase Press High Error (Usually CCV Filter?) Yes L01 No NA
CA559 Rail pressure low / Supply pump pressure low (Usually Filters?) Yes L01 No NA
Rail press valve Trip Error, Insite needed to run pressure test, (Usually
CA3741 Yes 15%
Filters?) Yes L03 NA
IMV solenoid error, Resistance Ώ of actuator circuit is high or low. (Usually
CA2311 Yes 15%
Filters?) Yes L03 NA
CA2249 RAIL PRESS VERY LOW ERROR (Usually Filters?) Yes L03 Yes 15% NA
Understanding Engine Management CPUs and Adaptive Memory Logic
Four Basic Computer Functions: Examples of Different Names for Controllers:
1. Input 1. ISO Name: CPU or Central Processing Unit
2. Processing 2. PCM or Power train Control module
3. Storage 3. ECM or Engine Control module
4. Outputs 4. Komatsu PCM or Pump Controller Module
Computers have two types of Storage:
A. Permanent (ROM) Read only Memory
1. ROM or Read Only Memory, where permanent programming is stored
2. PROM Programmable Read Only Memory, Firmware, Machine faults, and calibrations
3. EEPROM or Electrical Erasable & Programmable, Firmware, calibrations, and adaptive memory
B. Temporary Memory:
There are two types of RAM or Random Access Memory used in engine CPU management
1. Volatile RAM, loses memory as soon as battery power is lost, Switched Power, Fault codes
2. Nonvolatile or KAM or Keep Alive Memory, Un-switched power, Fault codes
Note vital information stored in KAM can stored in back-up files in multiple controllers
CPUs are continuously supplied information from RAM & KAM:
Continuous Monitors information held in KAM
Example: Stores memory of total idle time and last Active or Manual regenerations
This allows the controller to know when to request a Desorb or Mandatory 96 Hr regeneration
Non-continuous Monitors information held in RAM:
Examples: Current DPF temperatures, MAS readings, Ambient Air Pressure, Boost Pressure
Some CPU processing functions:
A. Rationality Testing
Example operator shifts machine from 4th speed to 2nd speed but Firmware logic has a conflict between
maximum 2nd gear speed and actual ground speed so action is disallowed
B. Functionality Testing
Example: At key on a114 engine the CPU receives 3 atmospheric pressures sensor readings.
The firmware logic mandates these readings be the same plus or minus a percentage. If the differential
pressure is out of the maximum range it will produce a fault code. (Non-functional)
C. Adaptive Memory stored in KAM
Emission controllers using Smart Sensors and Tamper Proof logic have Adaptive Memory.
Adaptive Memory will have back-up files stored in the Parent controller.
Example from B Functionality Testing:
1. If all sensors are in range "Functional" the CPU will average the three sensor readings.
Sensor 1, reads 100.5 kpa, Sensor 2, 99.0 kpa, Sensor 3, 99.8 kpa Average is 99.76 kpa
The CPU will adjust “adapt” sensor 1 by -.74% and does this for all three sensors and stores this
information in Adaptive memory. The CPU averages the next 40 or 50 cycles to make the readings
more accurate. Adaptive Memory will keeps adjusting the sensors readings based on CPU adjusted
values. Note when monitoring these readings you will see actual readings, “Before adjustment” even
though the fueling rates are being adjusted based on the percentage of change.
Example from B Functionality Testing:
2. If one sensor is out of range limits, firmware logic through the CPU performs at least 2 functions.
1. Generates a fault code, 2. Ignores readings from the faulty sensors and calculates sensor
readings based on other engine parameters and firmware logic. When a fault code is active
monitoring a faulty or replacement sensor you will not read actual sensor readings.
3. When a new sensor is installed adaptive memory will signal the CPU the censor is still faulty until
all logic mandated One Trip & Continuous Running Trip comparison test have been run.
If all Adaptive Memory files and it’s back-up files are erased the CPU looks at the actual readings.
Active Faults go inactive because sensor readings are in range and the adaptive process starts over.
Service Steps Before Diagnosing Excessive Regenerations on 107 & 114 Tier 4i Engines

Ø Take Engine Oil Sample every when troubleshooting DPF Regeneration issues

Ø Take Fuel Sample every when troubleshooting DPF Regeneration issues

Ø Reference and fill out FL12061A when troubleshooting DPF Regeneration issues

Ø Monitor MAF sensor readings at idle and high idle and compare readings to FN12061A

Ø Clean the Mass Air Flow sensor with MAF sensor cleaner, monitor and record readings

Ø Test for proper Air flow across the Charge Air Cooler and radiator and clean if needed

Ø Pressure test Charge Air Cooler and tubing for leaks

Ø Inspect exhaust tubing for both exhaust and fluid leaks

Ø Remove KCCV tubing at the intake for signs of engine oil entering the intake

Ø Check KCCV filter for being plugged with soot or damage

Ø Use compressed air and Brake Parts Cleaner to clean out CCV filter oil drain back hose

Ø Remove EGR Orifice Temp sensor and clean

Ø Inspect EGR supply tube for excessive soot build up

Ø Remove Exhaust Back Pressure Sensor and clean

Ø Blow compressed air into exhaust back pressure sensor manifold to test for obstruction

Ø 4.5 mm bore Scopes will fit through the temperature sensors mounting holes

Ø Use 4.5 mm bore Scope to inspect the DOC and DPF face for color and deposits

Ø Use Cummins Service Bulletin 4021600-03 to diagnose DOC and DPF deposits

Ø Use Cummins Service Bulletin 4021600-03 to diagnose face plugging

Ø Hook up Insite, start data logger, then start manual stationary Regeneration

Ø Perform Stationary Regen for Service after every DPF Cleaning or Replacement

Ø Record Dosing starting temperature for DOC in.

Ø Record all 3 maximum temperatures for DOC IN, DPF IN, and DPF OUT.

Ø Reference Insite KDPF Troubleshooting Cheat Sheet for 107 & 114 Tier 4i Engines
Insite KDPF Troubleshooting Cheat Sheet for 107 & 114 Tier 4i Engines

1. Normal Dosing starts at DOC Inlet temps of 250°C ± 20°C or 482°F ± 36ºF

2. Minimal DOC Inlet temps before Dosing starts, 230°C or 446°F

3. If Dosing starts before 446°F when viewing Insite the ECM is Faulty, period.
4. Maximum (Normal) DOC Inlet temps during Regeneration 385°C or 725°F.

5. Maximum (Normal) DPF Inlet and outlet temps during Regeneration,

565°C or 1050°F.
6. DPF Inlet and outlet regen temps higher than 1100°F is an over fueling condition.
a. Over-fueling can be either diesel fuel or oil
b. Dosing during manual regenerations uses all 6 injectors (Cummins Logic)
c. Dosing during Active regenerations uses injectors 4, 5, and 6.
d. Dosing fueling rates are controlled by the ECM based on KDPF temperatures
c. To date over-fueling (Diesel fuel) has always come from the injectors.
We have also experienced rebuilt injectors failing in a week’s time.
d. Engine oil over-fueling most of the time is caused by the KCC Filter overfilling
7. Usual causes for excessive oil entering the exhaust stream causing over-fueling:
a. Excessive blow by coming from turbo
b. Plugged or restricted check valve or drain back hoses for KCC filter housing.
c. Engines with high hours that plug the KCC filter prematurely could have high
blow-by cause by excessive compression rings or valve guide wear.
8. When DPF inlet and outlet temperatures are below 490°C or 914°F:
a. DOC cannot produce enough oxygen because of excessive soot or damaged.
b. The replacement DOC is faulty
c. ECM Firmware is damaged
d. Or b & c
Service Steps Before Diagnosing Excessive Regenerations on 125 & 140 Tier 4i Engines

Ø Take Engine Oil Sample every when troubleshooting DPF Regeneration issues

Ø Take Fuel Sample every when troubleshooting DPF Regeneration issues

Ø Reference and fill out FL12061A when troubleshooting DPF Regeneration issues

Ø Monitor MAF sensor readings at idle and high idle and compare readings to FN12061A

Ø Clean the Mass Air Flow sensor with MAF sensor cleaner, monitor and record readings

Ø Test for proper Air flow across the Charge Air Cooler and radiator and clean if needed

Ø Pressure test Charge Air Cooler and tubing for leaks

Ø Inspect exhaust tubing for both exhaust and fluid leaks

Ø Remove KCCV tubing at the intake for signs of engine oil entering the intake

Ø Check KCCV filter for being plugged with soot or damage

Ø Use compressed air and Brake Parts Cleaner to clean out CCV filter oil drain back hose

Ø Clean and inspect Dosing valve as this can easily raise DPF inlet temps substantially

Ø Use Cummins Insite to test Dosing valve and inspect for uniform spray pattern.

Ø 4.5 mm bore Scopes will fit through the temperature sensors mounting holes

Ø Use 4.5 mm bore Scope to inspect the DOC and DPF face for color and deposits

Ø Use Cummins Service Bulletin 4021600-03 to diagnose DOC and DPF deposits

Ø Use Cummins Service Bulletin 4021600-03 to diagnose face plugging

Ø Hook up Insite, start data logger, then start manual stationary Regeneration

Ø Perform Stationary Regen for Service after every DPF Cleaning or Replacement

Ø Record Dosing starting temperature for DOC in.

Ø Record all 3 maximum temperatures for DOC IN, DPF IN, and DPF OUT.

Ø Reference Insite KDPF Troubleshooting Cheat Sheet for 125 & 140 Tier 4i Engines
Insite KDPF Troubleshooting Cheat Sheet for 125 & 140 Tier 4i Engines

1. Normal Dosing starts at DOC Inlet temps of 290°C ± 20°C or 554°F ± 36ºF

2. Minimal DOC Inlet temps before Dosing starts, 250°C or 480°F

3. If Dosing starts before 480°F when viewing Insite the ECM is Faulty, period.
The Doser could be leaking but haven’t experienced a severe enough leak to be
noticeable or detectable viewing temperatures during regenerations.
4. Maximum (Normal) DOC Inlet temps during Regeneration 440°C or 824°F.

5. Maximum (Normal) DPF Inlet and outlet temps during Regeneration,

555°C or 1032°F.
6. DPF Inlet and outlet regen temps higher than 1100°F is an over fueling condition.
a. Over-fueling can be either diesel fuel or oil
b. I have not experienced over fueling (Diesel Fuel) caused by the Doser.
If doser is over-fueling I would suspect corrupted ECM Firmware but not a
damaged doser.
A leaking Doser generally cause excessive regens and a heavy buildup of
deposits over the Doser not elevated temperatures during dosing.
c. Doser fueling rates are controlled by the ECM based on KDPF temperatures
d. To date Over fueling (Diesel fuel) has always come from the injectors.
We have also experienced rebuilt injectors failing in a week’s time.
e. Engine oil over fueling most of the time is caused by the KCC Filter overfilling
7. Usual causes for excessive oil entering the exhaust stream causing over-fueling:
a. Excessive blow by coming from turbo
b. Plugged or restricted check valve or drain back hoses for KCC filter housing.
c. Engines with high hours that plug the KCC filter prematurely could have high
blow-by cause by excessive compression ring or valve guide wear.
8. When DPF inlet and outlet temperatures are below 487°C or 910°F
a. DOC cannot produce enough oxygen because of excessive soot or damaged.
b. The Doser is covered over with deposits or malfunctioning for various reasons
c. ECM Firmware is damaged
d. The replacement DOC is faulty
e. Or c & d
 Time Suggested Preventative Maintenance for Tier 4i Engines
Minutes Suggested Preventive 1,000 Hour Tier 4i Engine Maintenance Estimated Time, 5.5 hours Diagnose or Prevent
15 Complete Battery/Starter/Charging Analization to prevent Fault Code CA1117, (Midtronics EXP-1000 HD) ECM Firmware Damage
15 Clean Mass Air Flow sensor and laminar flow screen Over-fuel /DOC Damage
20 Blow compressed air through the Charge Air Cooler and radiator to test for obstructions and clean as needed Over-fuel /DOC Damage
15 Visually inspect and torque on all hose clamps for Charge air Cooler and intake hoses Over-fuel /DOC Damage
10 Visually inspect complete exhaust, EGR, & Turbo piping system for exhaust and fluid leaks Inefficient long Regens
10 Remove KCCV rubber tubing connector at intake for signs of engine oil entering the intake Over-fuel /DOC Damage
85 If there are signs of engine oil entering the intake perform steps A, B, and C Over-fuel /DOC Damage
20 A: Remove KCCV intake tube assembly and clean out with brake parts cleaner Over-fuel /DOC Damage
10 B: Use compressed air and Brake Parts Cleaner to flush out the CCV filter oil drain back hose Over-fuel /DOC Damage
30 C: Perform engine Blow by test Over-fuel /DOC Damage
20 Test EGR & KVGT boost oil pressure Over-fuel /DOC Damage
10 Remove EGR Orifice Temp sensor and clean 107 & 114 Engines only Excessive Regens
10 Inspect EGR supply tube for excessive soot build up 107 & 114 Engines only Excessive Regens
10 Remove Exhaust Back Pressure Sensor and clean 107 & 114 Engines only Excessive Regens
10 Blow compressed air into exhaust back pressure sensor manifold to test for obstruction 107 & 114 Engines only Excessive Regens
20 Remove Doser clean, do not disconnect water or fuel lines. Dosers are installed 125/140 engines only Over-fuel /DOC Damage
10 Dosers with excessive carbon build-up, leave unbolted from manifold and run engine at idle for 1 minute to test for leaks Over-fuel /DOC Damage
10 Dosers with excessive carbon build-up, leave unbolted from manifold and run Insite Doser test to check spray pattern Inefficient long Regens
160 4.5 mm Bore Scopes will fit through the temperature sensors mounting holes Proper Diagnoses of KDPF
10 Use 4.5 mm bore Scope to inspect the DOC and DPF face for color and deposits Proper Diagnoses of KDPF
5 Use Cummins Service Bulletin 4021600-03 to diagnose DOC and DPF deposits Proper Diagnoses of KDPF
5 Use Cummins Service Bulletin 4021600-03 to diagnose face plugging Proper Diagnoses of KDPF
40 Hook up Insite, start data logger, then start manual stationary regeneration for 30 minutes minimum Over-fuel /DOC Damage
0 Record Dosing starting temperature for DOC in. ECM Firmware Damage
5 Record all 3 maximum temperatures for DOC IN, DPF IN, and DPF OUT. Proper Diagnoses of KDPF
5 Reference Insite KDPF Troubleshooting Cheat Sheet for 107/114 Tier 4i Engines Proper Regen Diagnoses
70