Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction
Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction
Contents
Product Affected
Symptom:
A combination of one or all DEF header fault code(s) 3868, 4572 and/or 4677 are
logged.
Engine has a DEF header malfunction and replacement is not available.
Root Cause:
DEF header replacement parts are not available and DEF header part shortages have
necessitated the release of an ECM calibration code revision that reduces engine
torque
and vehicle speed limits levels to allow for continued operation of the vehicle until a DEF
header is available for
final repair.
Verification
Verify one or all DEF header datalink Fault Codes 3868, 4572 and/or 4677 are logged.
Verify published troubleshooting has been completed.
Verify DEF header part is not available for the repair.
Resolution
Because of the lack of DEF header part availability, new ECM calibration codes are
being made available that reduces the inducement
levels when DEF header datalink
communication faults are detected.
Downloading this ECM calibration code must be filed in accordance with one of the
appropriate TRPs. See TRP2484 or TRP2489 for further details.
TRP2489 – qualified engines installed in Navistar® chassis
TRP2484 – qualified engines installed in the following chassis types.
Tico
Additional chassis types will be added as they become eligible
Unauthorized download of this ECM calibration code is considered tampering of
emission control devices on Cummins products.
Cummins Inc. prohibits tampering of
emissions control devices on Cummins® products in any capacity. Reference Warranty
Memo
1633 for additional details. See link below.
Note
:
https://quickserve.cummins.com/protected/files/qsol/en/warranty/memos/m1633.pdf
(https://quickserve.cummins.com/protected/files/qsol/en/warranty/memos/m1633.pdf)
Customer Communication
This communication is for information purposes only and to help provide clear
communication to the customer.
Because of a global shortage of parts in the industry, as a result of unprecedented
demand in the wake of the global pandemic
and other events beyond the
manufacturers’ control, an ECM calibration code solution is being provided that
reduces the inducement
levels when DEF header datalink communication faults
are detected. Fault codes 3868, 4572 and/or 4677 could be active but
no amber
check engine light illuminated indicating there is no communication between the
engine and DEF header, however the
vehicle will be allowed to operate normally
without engine torque and vehicle speed limits.
DEF Level indicator will not provide an accurate reading and is not indicative of
amount of DEF available in the tank. See Table 1.
The DEF fluid level in the tank will need to be manually inspected to allow proper
vehicle operation.
By agreeing to this repair, one is agreeing to make the vehicle available at a later
date once DEF header parts are available.
A future communication will be sent to
make these arrangements.
DEF quality, DEF temperature and DEF level in the electronic service tool will not read
correctly.
These products have new corresponding engine ECM calibrations codes that align with
the repair.
A Fleet Count will be required to install the new ECM calibration code.
See appropriate table below for ECM calibration code mapping.
Fault Codes 3868, 4572 and/or 4677 will still be active.
Running an engine that is not properly maintained such as without DEF or improper
DEF quality are conditions that are consider customer abuse. Reference
Responsibilities
procedure in the Warranty Administration Manual.
Note
:
https://quickserve.cummins.com/qs3/pubsys2/xml/en/procedures/111/111-
502-003.html
(https://quickserve.cummins.com/qs3/pubsys2/xml/en/procedures/111/111-
502-003.html)
Table 1, Changes to ECM Calibration Code with New ECM Calibration Code with No
Torque Or Speed Inducement(s) with any Combination
of Affected Fault Codes
With Existing ECM With New ECM Calibration
Item
Calibration Code Code
Amber lamp and
Malfunction indicator lamp No lamps/ no torque and
FC3868
(MIL)/Torque and speed speed inducement
inducement
Amber lamp and
No lamps/ no torque and
FC4572 MIL/Torque and speed
speed inducement
inducement
Amber lamp and
No lamps/ no torque and
FC4677 MIL/Torque and speed
speed inducement
inducement
DEF gauge is not DEF gauge is not
DEF Level accurate/Electronic service accurate/Electronic service
tool is not accurate tool is not accurate
Electronic service tool is not Electronic service tool is not
DEF Temperature
accurate accurate
Electronic service tool is not Electronic service tool is not
DEF Quality
accurate accurate
Table 2, ECM Calibration Code Mapping for X15 CM2350 X114B And X15 CM2350
X116B
Existing ECM Calibration Code New ECM Calibration Code
HD10001 HD10500
HD10002 HD10492
HD10005 HD10504
HD10008 HD10522
HD10009 HD10528
HD10011 HD10488
HD10012 HD10496
HD10014 HD10508
HD10024 HD10538
HD10025 HD10540
HD10030 HD10546
HD10031 HD10550
HD10032 HD10554
HD10036 HD10558
HD10037 HD10562
HD10038 HD10566
HD10043 HD10520
HD10044 HD10524
HD10045 HD10526
HD10048 HD10516
HD10050 HD10517
HD10054 HD10489
HD10055 HD10490
HD10056 HD10491
HD10057 HD10493
HD10058 HD10494
HD10059 HD10495
HD10060 HD10497
HD10061 HD10498
HD10062 HD10499
Table 2, ECM Calibration Code Mapping for X15 CM2350 X114B And X15 CM2350
X116B
Existing ECM Calibration Code New ECM Calibration Code
HD10072 HD10501
HD10073 HD10502
HD10074 HD10503
HD10075 HD10505
HD10076 HD10506
HD10077 HD10507
HD10078 HD10509
HD10079 HD10510
HD10080 HD10511
HD10087 HD10512
HD10089 HD10513
HD10091 HD10521
HD10094 HD10523
HD10097 HD10525
HD10100 HD10527
HD10103 HD10529
HD10114 HD10539
HD10115 HD10541
HD10126 HD10547
HD10127 HD10548
HD10128 HD10549
HD10129 HD10551
HD10130 HD10552
HD10131 HD10553
HD10132 HD10555
HD10133 HD10556
HD10134 HD10557
HD10144 HD10559
HD10145 HD10560
HD10146 HD10561
Table 2, ECM Calibration Code Mapping for X15 CM2350 X114B And X15 CM2350
X116B
Existing ECM Calibration Code New ECM Calibration Code
HD10147 HD10563
HD10148 HD10564
HD10149 HD10565
HD10150 HD10567
HD10151 HD10568
HD10152 HD10569
HD10162 HD10570
HD10164 HD10571
HD10169 HD10574
HD10170 HD10575
HD10171 HD10576
HD10172 HD10577
HD10173 HD10578
HD10174 HD10579
HD10175 HD10580
HD10176 HD10581
HD10177 HD10582
HD10178 HD10583
Table 2 Continued
HD10179 HD10584
HD10180 HD10585
HD10181 HD10586
HD10182 HD10587
HD10183 HD10588
HD10184 HD10589
HD10185 HD10518
HD10186 HD10519
HD10187 HD10530
HD10188 HD10531
HD10189 HD10532
Table 2 Continued
HD10190 HD10533
HD10191 HD10534
HD10192 HD10535
HD10193 HD10536
HD10194 HD10537
HD10195 HD10542
HD10196 HD10543
HD10197 HD10544
HD10198 HD10545
HD10199 HD10572
HD10200 HD10573
HD10201 HD10590
HD10202 HD10591
HD10203 HD10592
HD10204 HD10593
HD10205 HD10594
HD10206 HD10595
HD10207 HD10596
HD10208 HD10597
HD10209 HD10598
HD10210 HD10599
HD10211 HD10600
HD10212 HD10601
HD10213 HD10602
HD10214 HD10603
HD10215 HD10604
HD10216 HD10605
HD10217 HD10514
HD10218 HD10515
HD10219 HD10606
HD10220 HD10607
HD10221 HD10608
Table 2 Continued
HD10222 HD10609
HD10223 HD10610
HD10224 HD10611
HD10225 HD10612
HD10226 HD10613
HD10227 HD10614
HD10228 HD10615
HD10229 HD10616
HD10230 HD10617
HD10231 HD10618
HD10232 HD10619
HD10233 HD10620
HD10234 HD10621
HD10235 HD10622
HD10236 HD10623
HD10237 HD10624
HD10238 HD10625
HD10239 HD10626
HD10240 HD10627
HD10241 HD10628
HD10242 HD10629
HD10243 HD10630
HD10244 HD10631
HD10245 HD10632
HD10246 HD10633
HD10247 HD10634
HD10248 HD10635
HD10249 HD10636
HD10250 HD10637
HD10251 HD10638
HD10252 HD10639
HD10253 HD10640
Table 2 Continued
HD10254 HD10641
HD10255 HD10642
HD10256 HD10643
HD10257 HD10644
Table 2 Continued
HD10258 HD10645
HD10259 HD10646
HD10260 HD10647
HD10261 HD10648
HD10262 HD10649
HD10263 HD10650
HD10264 HD10651
HD10265 HD10652
HD10266 HD10653
HD10267 HD10654
HD10268 HD10655
HD10269 HD10656
HD10270 HD10657
HD10271 HD10658
HD10272 HD10659
HD10273 HD10660
HD10274 HD10661
HD10275 HD10662
HD10276 HD10663
HD10277 HD10664
HD10278 HD10665
HD10279 HD10666
HD10280 HD10667
HD10281 HD10668
HD10282 HD10669
HD10283 HD10670
HD10284 HD10671
Table 2 Continued
HD10285 HD10672
HD10286 HD10673
HD10287 HD10674
HD10288 HD10675
HD10289 HD10676
HD10290 HD10677
HD10291 HD10678
HD10292 HD10679
HD10293 HD10680
HD10294 HD10681
HD10295 HD10682
HD10296 HD10683
HD10297 HD10684
HD10298 HD10685
HD10299 HD10686
HD10300 HD10687
HD10301 HD10688
HD10302 HD10689
HD10303 HD10690
HD10304 HD10691
HD10305 HD10692
HD10306 HD10693
HD10309 HD10694
HD10310 HD10695
HD10313 HD10696
HD10314 HD10697
HD10317 HD10698
HD10318 HD10699
HD10321 HD10700
HD10322 HD10701
HD10325 HD10702
HD10326 HD10703
Table 2 Continued
HD10329 HD10704
HD10330 HD10705
HD10331 HD10706
HD10332 HD10707
HD10333 HD10708
HD10334 HD10709
HD10335 HD10710
HD10336 HD10711
HD10337 HD10712
HD10338 HD10713
HD10339 HD10714
HD10340 HD10715
HD10341 HD10716
HD10342 HD10717
HD10343 HD10718
HD10344 HD10719
HD10345 HD10720
HD10346 HD10721
HD10347 HD10722
HD10348 HD10723
Table 2 Continued
HD10349 HD10724
HD10350 HD10725
HD10351 HD10726
HD10352 HD10727
HD10353 HD10728
HD10354 HD10729
HD10355 HD10730
HD10356 HD10731
HD10357 HD10732
HD10358 HD10733
HD10359 HD10734
Table 2 Continued
HD10360 HD10735
HD10361 HD10736
HD10362 HD10737
HD10363 HD10738
HD10364 HD10739
HD10365 HD10740
HD10366 HD10741
HD10367 HD10742
HD10368 HD10743
HD10369 HD10744
HD10370 HD10745
HD10371 HD10746
HD10372 HD10747
HD10373 HD10748
HD10374 HD10749
HD10375 HD10750
HD10376 HD10751
HD10377 HD10752
HD10378 HD10753
HD10379 HD10754
HD10380 HD10755
HD10381 HD10756
HD10382 HD10757
HD10383 HD10758
HD10384 HD10759
HD10385 HD10760
HD10386 HD10761
HD10387 HD10762
HD10388 HD10763
HD10389 HD10764
HD10390 HD10765
HD10391 HD10766
Table 2 Continued
HD10392 HD10767
HD10393 HD10768
HD10394 HD10769
HD10395 HD10770
HD10396 HD10771
HD10397 HD10772
HD10398 HD10773
HD10399 HD10774
HD10400 HD10775
HD10401 HD10776
HD10402 HD10777
HD10403 HD10778
HD10404 HD10779
HD10405 HD10780
HD10406 HD10781
HD10407 HD10782
HD10408 HD10783
HD10409 HD10784
HD10410 HD10785
HD10411 HD10786
HD10412 HD10787
HD10413 HD10788
HD10414 HD10789
HD10415 HD10790
HD10416 HD10791
HD10417 HD10792
HD10418 HD10793
HD10419 HD10794
HD10420 HD10795
HD10421 HD10796
HD10422 HD10797
HD10423 HD10798
Table 2 Continued
HD10424 HD10799
HD10425 HD10800
HD10426 HD10801
HD10427 HD10802
Table 2 Continued
HD10428 HD10803
HD10429 HD10804
HD10430 HD10805
HD10431 HD10806
HD10432 HD10807
HD10433 HD10808
HD10434 HD10809
HD10435 HD10810
HD10436 HD10811
HD10437 HD10812
HD10438 HD10813
HD10439 HD10814
HD10440 HD10815
HD10441 HD10816
HD10442 HD10817
HD10443 HD10818
HD10444 HD10819
HD10445 HD10820
HD10446 HD10821
HD10447 HD10822
HD10448 HD10823
HD10449 HD10824
HD10450 HD10825
HD10451 HD10826
HD10452 HD10827
HD10455 HD10828
HD10456 HD10829
Table 2 Continued
HD10457 HD10830
HD10458 HD10831
HD10459 HD10832
HD10460 HD10833
HD10461 HD10834
HD10462 HD10835
HD10463 HD10836
HD10464 HD10837
HD10465 HD10838
HD10466 HD10839
HD10467 HD10840
HD10468 HD10841
HD10469 HD10842
HD10470 HD10843
HD10471 HD10844
HD10472 HD10845
HD10473 HD10846
HD10474 HD10847
HD10475 HD10848
HD10476 HD10849
HD10477 HD10850
HD10478 HD10851
HD10479 HD10852
HD10480 HD10853
HD10481 HD10854
HD10482 HD10855
HD10483 HD10856
HD10484 HD10857
HD10485 HD10858
HD10486 HD10859
Table 3, ECM Calibration Code Mapping for X15 CM2450 X124B and X15 CM2450
X134B
Table 3, ECM
Existing ECM Calibration
Calibration Code
Code Mapping for X15
NewCM2450
ECM Calibration
X124B and Code
X15 CM2450
X134B
Document History
Date Details
2021-8-26 Module Created
Last Modified: 16-Sep-2021