FPT Engine Troubleshooting Manual Rev1.1

1
FPT Engine Troubleshooting Manual
Version 1.1
Table of Contents
SECTION PAGE
1. Opening E.A.S.Y and Connecting to Machine 5 - 19
2. Menu Descriptions 20- 23
3. T4F – EDC 71CV41 24
3.1 Reading Fault Codes 25-27
3.2 Saving Fault Codes 28-30
3.3 Clearing Fault Codes 31
3.4 Trip Recorder 32
3.5 Saving Trip Recorder 33-37
3.6 Counters Reset 38-46
TORQUE LIMITATION ACTIVE 47-48
DEF DEFROST MODE 49-53
3.7 UDST (Urea Dosing System Test) 54-68
3.8 UDLC (Urea Dosing Leak Check) 69-81
3.9 UDVC (Urea Dosing Valve Check) 82-90
3.10 UDPC(Urea Dosing Pump Check) 91-100
2
Table of Contents
SECTION PAGE
T4F – EDC 71CV41(Cont’d)
3.11 Active Diagnosis 101-104
Pre Heater Resistance 105-106

Flap Actuator Position 107-108
Engine Speed 109-112
Rail Pressure 113-116
Engine Temperature 117-120
Read Parameters 121-124
Injector Cut Out 125-131
3.12 Parameter Grouping and Graphing 132-148
3.13 Flap Valve Test 149-155
3.14 DEF Supply Module Flushing Procedure 156-164
3
Table of Contents
SECTION PAGE
4. T4i ECM – EDC 7 UC31- K Line 165
4.1 Connecting to Engine ECU 166-174
4.2 Reading and Saving Engine Fault Codes 175-179
4.3 Clearing Engine Fault Codes 180-182
4.4 Reading and Saving Log File (Data Stored) 183-186
4.5 Counters Reset 187-196
4.6 Reading and Grouping Parameters 197-214
4.7 Active Diagnosis 215-222
5. T4i Denoxtronic 2 223
5.1 Connecting to DCU 224-232
5.2 Reading and Saving DCU Fault Codes 233-237
5.3 UDST 238-249
5.4 Dosing Valve Test 250-257
4
1. Initial set up of EASY software
Prior to attempting to connect the tablet or laptop to a machine

the software should be checked first.
Perform a E.A.U.S update to ensure the latest software version.
This can save valuable time so a technician does not travel to a
machine and find they cannot connect because there was an
issue with the initial set up.
PT Box
The PT Box is the interface that allows the Engine ECU to

communicate with the tablet or laptop
1. Opening E.A.S.Y and Connecting to
Machine
Connect to the machine in this order.

1. Ensure ignition key is OFF
2. Connect the PT Box to the machine
3. Connect the PT Box to the laptop/notepad
4. Turn the ignition key on.
NOTE: When using the program there is sometimes a delay after

clicking on the prompts. Please be patient and avoid clicking
repeatedly which may cause the program to freeze.
Connecting PT Box to Engine
Computer to PT-Box
PT-Box
PT-Box to Diagnostic Port (2 Cables)

8
Opening E.A.S.Y Diagnostic Software
1. Select E.A.S.Y Icon on desktop. A window

will pop up asking you to allow the program to
make changes to your computer. Select yes.
When the General Rules for Use window pops
up click on ACCEPT and then the green tick
2. Select ‘Accept’ 3. Select Checkmar
9
Electronic System Engine Screen
Click on Electronic System Engine and then click on the

green arrows in the bottom right.
1. Select
10
Select ECI Screen
Click on the green tick in the bottom right.
Select
11
ECU/DCU Selection Screen
Select the appropriate ECU to be viewed. Select ECM-EDC17CV41

ECM-EDC17CV41 will access the engine ECU on T4f engines
DENOXTRONIC 2 will access the DENOX system on T4i engines.
ECM-EDC 7 UC31– K LINE will access the engine ECU on T4i engines
1. Select
2. Select
12
Acceptance of Engine Screen
Click on the green tick in the ATTENTION box.
13
Ignition Key Mode Screen
Click on MANUAL in the IGNITION KEY box.
Select
14
Turn the Ignition Key ON
Click on the green tick box.
15
Engine Data Screen
When the ENGINE DATA window pops up check there is a 15

digit ENGINE ID number and then click on SAVE AND EXIT.
If there is not a 15 digit ENGINE ID number type the number
000123456789.000 and then click on SAVE AND EXIT.
Select
16
ATTENTION Screen
Click on the green tick.
17
Now Online and ready for diagnostics
Once arriving at this screen, diagnostics and testing are now available.
The green online box should be visible on the bottom left of the
screen. Note: The DIAGNOSIS, TEST and SPECIAL FUNCTIONS
have a 2nd page of selections which are on the next page.
18
Now Online and ready for diagnostics
2nd Page
The 2nd page of selections can be accessed by clicking on the
arrows as circled below.
19
2. Menu Descriptions
DIAGNOSIS
IDENTIFICATION CODE READING – Not used
FAULTS MEMORY READING

Provides a list of present(active) and intermittent fault codes. In this
menu fault codes can be saved or cleared.
PARAMETERS READING
Monitors various engine parameters. Able to select various engine
groups and time frame and sample rate.
DATA STORED
Stored data from the engine parameters for the life of the machine
20
Menu Descriptions
PROGRAMMING
PROGRAMMING
Not used
VEHICLE DATA
Not Used
21
Menu Descriptions
TEST
ACTIVE DIAGNOSIS
Menu for activating various components on the engine including grid
heater, exhaust flap actuator. Can change engine speeds in this menu.
ENGINE TEST
Menu for testing engine performance. Cylinder and injector comparison.
FLAP VALVE TEST

Menu for testing exhaust flap valve and actuator.
UDST (UREA DOSING SYSTEM TEST)

Menu for testing aftertreatment system, including DEF tank, DEF pump,
dosing injector and purge system.
22
Menu Descriptions
SPECIFIC FUNCTIONS
COMPONENT REPLACEMENT
Not used.
FORCED REGENERATION: NORMAL MODE

Not used
INDUCEMENT COUNTERS RESET FOR SERVICE

Menu to enable the engine to temporarily return to full power following
a derate due to a fault detection.
INDUCEMENT EDC17CV41 EURO VI

Not used
23
3. ECM – EDC17CV41
Tier 4 Final Engine ECU Connection
3.1 READING FAULT CODES
To access the engine fault codes click on FAULTS MEMORY READING

and then the green arrows at the bottom right of the screen.
25
READING FAULT CODES
The example below shows that there are 20 PRESENT (active) codes
and no INTERMITTENT codes. To check the details of the code in the
Fault Code List use the 4 digits of the DTC FNR number after the 0x as
shown below. The code to be used in the example below is 11E3
Fault Code
26
READING FAULT CODES
To show the next code click on the arrow(circled) to scroll to the

next page. After scrolling to the next fault code you must click on
the new fault code line to view the new DTC FNR number. The
code below is 956B
Click to
view
number
27
3.2 SAVING FAULT CODES TO A FILE
To save the fault codes to a file click on the folder icon at the
bottom of the screen.
Select
28
SAVING FAULT CODES TO A FILE
Click on the printer icon at the bottom of the screen. A printer

choice window will pop up. Select Microsoft XPS Document Writer
and then click on Print.
Select
Select
29
SAVING FAULT CODES TO A FILE
Select a location where you want to save the file(desktop shown in

example) and then name the file to include the current date
(yymmdd) ,machine serial number and Fault Codes, then select save.
Select
location
Name file
Save
30
3.3 CLEARING FAULT CODES
To clear the stored (intermittent) fault codes click on Cancel Faults Memory
at the bottom of the screen and then click the green tick in the pop up box.
NOTE: Active (present) faults cannot be cleared and must be repaired.
Select
Select
31
3.4 ENGINE TRIP RECORDER
To access the trip recorder click on DIAGNOSIS and then click on

DATA STORED. The DATA STORED menu will provide the
operating history (trip recorder) of the engine.
Select
32
3.5 SAVING ENGINE TRIP RECORDER FILE
Use the arrows to scroll up or down to view the stored data.

To save a file of the trip recorder (DATA STORED) click on the file
icon at the bottom of the screen.
Select to Use
save file arrows
to
scroll
33
SAVING ENGINE TRIP RECORDER FILE
A new Data Stored screen will appear. Click on the printer icon at
the top left of the screen.
Select
34
A printer choice window will pop up. Select Microsoft XPS

Document Writer and then click on Print.
Select
35
example) and then name the file to include the current date (yymmdd),
machine serial number and Data Stored, then select save.
Select location
Name file
Save
36
A Data stored window will pop up advising the file has been saved
(Report correctly generated). Click on the green tick to finish.
37
3.6 COUNTER RESET
If a machine detects 3 consecutive aftertreatment faults then Severe

Inducement (Engine Derate) is activated. Once the fault is repaired a
COUNTER RESET is necessary to cancel the Severe Inducement. From the
Main Menu click on the arrow(circled) to scroll to page 2 of the SPECIFIC
FUNCTIONS menu.
38
COUNTER RESET
Click on INDUCEMENT COUNTER RESET FOR SERVICE and

then click on the green arrows
39
COUNTER RESET
An ATTENTION window will pop up. Click on the green tick.
40
COUNTER RESET
Click on INDUCEMENT COUNTER RESET FOR SERVICE and

then click on the green arrows(circled).
41
COUNTER RESET
Turn the ignition switch OFF and then click on the green tick.
42
COUNTER RESET
Click on the INDUCEMENT COUNTER RESET FOR SERVICE

box.
43
COUNTER RESET
Turn the ignition switch ON and then click on the green tick.
44
COUNTER RESET
Turn the ignition switch OFF and then click on the green tick.
45
COUNTER RESET
The screen below will appear to indicate the Counter Reset was
successful.
46
TORQUE LIMITATION ACTIVE
SPN-64911 / DTC-FD8F
Info: Torque limitation active
Module: ECU
Context:
The Engine Control Unit (ECU) monitors the emissions control system
functionality and efficiency. When a technical fault occurs that may affect either
the functionality or the efficiency of the emissions control system the ECU will
impose a performance limitation in compliance with OBD legislation.
Cause:
A technical fault related to the emissions control system has been detected
causing a torque limitation.
47
TORQUE LIMITATION ACTIVE
Solution:
This fault code is for information only. There is an active performance limitation due to OBD
legislation. This fault was caused by an emissions relevant technical fault. Check the vehicle
display for any other emissions relevant faults. The vehicle control module (VCM) alarm log
should be saved and checked for any codes relevant to the technical fault that has occurred.
If any other emissions relevant fault codes are present (active or inactive) then address
these codes first before continuing.
If no other emissions relevant fault codes are present and active then heal the code by
completing x2 driving cycles as detailed below.
With the key OFF wait 90 seconds, turn the key to ON and then START the engine. Run
the engine for 10 seconds then turn the key to OFF. Complete x2 of these cycles to
heal the code.
48
DEF DEFROST MODE
If performing after-treatment tests with the PT-BOX in cold weather and the
temperature is below the required setting an ADBLUE DEFROST error message will
be displayed (Fig. 1) and prevent after-treatment diagnosis tests from being
performed.
Figure 1 – DEF defrost mode error
49
DEF DEFROST MODE
REQUIRED ACTION: Validate DEF tank temperature before starting any

after-treatment diagnosis tests.
PROCEDURE: Before starting work, read and follow all “servicing safety
precautions” as listed in the machine and attachment operating/service
manuals and parts catalogs.
Start the engine and validate the DEF tank temperature with the PT-Box.
Select the “DIAGNOSIS” menu then “PARAMETER READINGS” and cycle
through the pages until “ADBLUE TANK TEMPERATURE” is read. This will
display the current DEF temperature reading from the DEF tank.
See (Fig. 2)
50
DEF DEFROST MODE
Fig. 2
51
DEF DEFROST MODE
Fig. 2
52
DEF DEFROST MODE
1. A minimum DEF tank temperature of 22° Celsius (72° Fahrenheit) is needed

before performing any after-treatment diagnosis. If the temperature is below
22° C set the machine to high idle to warm the temperature to 22° C.
2. If the machine is in derate a counter reset will need to be done to enable the
machine to run at high idle.
3. Once the DEF tank temp is at required temperature the after-treatment

diagnosis tests can be performed. If the engine is turned off to run an after
treatment test in cold weather the machine may have to be restarted and
warmed up again for a few minutes to resume testing.
4. Any active codes for the dosing module or supply module will also prevent
after-treatment diagnosis tests from being performed. All active codes need to
be addressed and resolved before proceeding with diagnosis.
53
3.7 UDST (UREA DOSING SYSTEM TEST)
Before performing the UDST the following criteria must be met:

• Minimum DEF tank temperature of 22o Celsius (72o Fahrenheit)
• If temperature is below required setting an ADBLUE DEFROST error
message will be displayed and prevent after-treatment diagnosis tests to
be performed.
• Any active codes for the dosing module or supply module will also prevent
after-treatment diagnosis tests to be performed.
• If the machine is in derate a counter reset will need to be done to enable
the machine to run at high idle.
• Once the DEF tank temp is at required temperature the after-treatment
54
3.7 UDST (UREA DOSING SYSTEM TEST)
The UDST menu allows for the dosing system to be checked. This
test will activate all phases of the dosing system including the
pump, injector and reverting valve. An example of a passed system
check and times lines is shown below.
Pressure
Pump duty cycle drops as
slows as pressure injector turns Pressure rises
reaches threshold on as injector turns
off
Pump Start of
turned on purge cycle
Injector
Vacuum Pressure turned off Pump
created builds Injector turned on
during purge turned on
Vacuum created
cycle
during purge cycle
Reverting
valve turned
55
on
To activate the UDST click on TEST and then click on UDST.
NOTE: The test will be done with the key on and with the engine
not running.
Select
Select
56
A warning window will appear, click the green tick to continue.
57
An ignition key window will appear, ensure the ignition key is on
and click the green tick to continue.
58
A connection open window will appear, wait until the next screen
appears.
59
A selection menu will appear, click on UDST and then click on RUN
UDST.
Select
Select
60
An information screen will appear describing what can and can’t be
diagnosed by the test, click on green tick to continue.
61
An ATTENTION! screen will appear advising not to carry out more
than two consecutive UDST tests without running the engine until
the catalyst working temperature is reached. Click on the green tick
to continue.
62
Ensure the engine is not running and click on the green tick to
continue.
63
Ensure the ignition key is on and click on the green tick to

continue.
64
The following screen will appear. Please wait until the test starts.
65
The following screen will appear and the test will begin. The test
will take about 2 minutes.
66
UDST (PASS)
If the UDST test is OK the following screen will appear.
67
UDST (FAILURE)
If the UDST test fails the following screen will appear indicating the
UDST error mode and troubleshooting guide.
68
3.8 UDLC (UREA DOSING LEAK CHECK)
Before performing the UDLC the following criteria must be met:
be performed.
69
3.8 UDLC (UREA DOSING LEAK CHECK)
WARNING: The following test pressurizes the system. Wear work gloves and
safety goggles for protection.
Remove the Dosing Injector from the DOC so it can be observed for leaks.
The UDLC test allows checks to be made for any leaks in the system. Navigate to
the UDST menu as described above in the UDST test. Click on UDLC and in the
dropdown box that appears click on CARRY OUT PRESSURE MAINTENANCE
TEST.
70
UDLC (UREA DOSING LEAK CHECK)
An information screen will appear, click on green tick to continue.
71
A warning screen will appear, ensure engine is not running and

click on green tick to continue.
72
An Ignition Key screen will appear, click on green tick to continue.
73
This screen will appear, wait until the test begins.
74
The test begins. As the test runs inspect the pressure line from the DEF
Supply Module to the Dosing Injector for any leaks. Check that there is
no leakage from the Dosing Injector or the DEF Supply Module.
75
The test will take about 4 minutes. The system pressure (red line) should
stay at 9000 mbar for the duration of the test and the Duty Cycle should
stay under 20%. Click on the green tick.
76
SAVING UDLC GRAPH
Click on UDLC and in the dropdown box click on LOAD REPORT.
77
SAVING UDLC GRAPH
Click on file just created (identified by date) and then click on

Open.
78
SAVING UDLC GRAPH
The UDLC report will appear.
79
SAVING UDLC GRAPH
Click on UDLC and in the dropdown box click on SEE DIAGRAM

REPORT.
80
SAVING UDLC GRAPH
The UDLC graph will appear. Click on the green print icon and then save
the file to the desired location.
81
3.9 UDVC (UREA DOSING VALVE CHECK)
Before perform the UDVC the following criteria must be met:

be performed.
82
3.9 UDVC (UREA DOSING VALVE CHECK)
WARNING: The following test pressurizes the

system. Wear work gloves and safety goggles
for protection.
The UDVC cycles the dosing valve (injector) for
a set period of time and the volume of fluid
needs to be measured. To perform this test
remove the dosing injector from the DOC and
position into a measuring container. NOTE: Do
not use the type of container shown in the
photo. Use a tall narrow container to ensure all
the DEF is captured. The container should be
large enough to hold 500ml/17 fl oz.
83
UDVC (UREA DOSING VALVE CHECK)
To activate the UDVC test click on UDVC and then click on CARRY
OUT THE DOSING VALVE TEST.
Select
84
A DOSING VALVE CHECK screen will appear, click on the green

tick to continue.
85
Ensure the ignition switch is on and click on the green tick to

continue.
86
A Connection Opening in progress window will appear, wait until

the test starts.
87
Another window will appear, wait until the test starts.
88
The test will start and run for about four minutes.
89
At the conclusion of the test an Ignition Key window will pop up.
Turn the key off and then click on the green tick.
Measure the volume of DEF in the container. There should be 320
ml (+ or – 5%)
90
3.10 UDPC (UREA DOSING PUMP CHECK)
Before perform the UDPC the following criteria must be met:

be performed.
91
3.10 UDPC (UREA DOSING PUMP CHECK)
WARNING: The following test pressurizes the

system. Wear work gloves and safety goggles
for protection.
The UDPC cycles the dosing valve (injector) for
a set period of time and monitors the pump
pressure. To perform this test remove the
dosing injector from the DOC and position into
a measuring container. NOTE: The container
should be large enough to hold 1000ml/17 fl oz.
92
UDPC (UREA DOSING PUMP CHECK)
To activate the UDPC test click on UDPC and then click on CARRY
OUT THE SYSTEM EMPTYING TEST.
93
A screen will pop up describing the pump type. The test will use the
7.2kg/h type. Click on the green tick.
94
A system selection screen will pop up. Click on the 7.2kg/h type
and then click on the green arrows.
95
A warning screen will appear, ensure engine is not running and

click on green tick to continue.
96
An ignition key screen will appear, ensure the key is on and click
on green tick to continue.
97
A UDPC screen will appear, there will be a small delay before the
test starts.
98
The test will start and will run for about 5 minutes.
99
At the completion of the test measure the volume of DEF fluid.
There should be 585ml (+ or – 5%)
100
3.11 ACTIVE DIAGNOSIS
From the Main Menu the ACTIVE DIAGNOSIS menu allows certain
components to be tested or simulated. Click on ACTIVE
DIAGNOSIS and then the green arrows to access the menu.
101
ACTIVE DIAGNOSIS
102
ACTIVE DIAGNOSIS
The ACTIVE DIAGNOSIS menu consists 2 pages. Click on the

arrow(circled) to scroll to the 2nd page. Note: Not all menu items
are used. Those not used are shown in the next 2 pages.
Not used
Not used
Not used
Not used
103
ACTIVE DIAGNOSIS
2nd page.
Not used
104
PRE-HEATER RESISTANCE
Click on the PRE-HEATER RESISTANCE box and then the green

arrows(circled) to access this check.
105
PRE-HEATER RESISTANCE
Click on START to begin the test. The pre-heater (grid heater) will be
activated 3 times and you should be able to hear the audible click of the
relay operating. Voltage to the pre-heater can be checked with a voltmeter
106
FLAP ACTUATOR POSITION
Click on the FLAP ACTUATOR POSITION box and then the green
107
FLAP ACTUATOR POSITION
Click on the + or - boxes to manually move the position of the

exhaust flap.
108
ENGINE SPEED
Click on the ENGINE SPEED box and then the green

109
ENGINE SPEED
A CAUTION window will pop up. Click on the green tick.
110
ENGINE SPEED
Start the engine and then click on the green tick.
111
ENGINE SPEED
Click on the + or - boxes to manually increase or decrease the

engine speed.
112
RAIL PRESSURE
Click on the RAIL PRESSURE box and then the green

113
RAIL PRESSURE
114
RAIL PRESSURE
115
RAIL PRESSURE
Click on the + or - boxes to manually increase or decrease the fuel

rail pressure.
116
ENGINE TEMPERATURE
Click on the ENGINE TEMPERATURE box and then the green

117
ENGINE TEMPERATURE
118
ENGINE TEMPERATURE
119
ENGINE TEMPERATURE
Click on the + or - boxes to manually increase or decrease the

engine temp sensor reading.
This adjustment can be useful for checking the operation of the
cooling fan.
120
READ PARAMETERS
Click on the READ PARAMETERS box and then the green

121
READ PARAMETERS
122
READ PARAMETERS
123
READ PARAMETERS
Multiple injection parameters can now be viewed on one screen.
124
INJECTOR CUT OUT
Click on the INJECTOR CUT OUT box and then the green
arrows(circled) to access this test.
125
INJECTOR CUT OUT
126
INJECTOR CUT OUT
127
INJECTOR CUT OUT
The injector screen will pop up showing that all injectors are
enabled.
128
INJECTOR CUT OUT
By clicking on the enable box the injector can be disabled. Click

back on the box to turn the injector back on. Note: The injector
cylinder numbers above the boxes is the order in which the
cylinders fire in the firing order for the engine. It is not the
physical injector number
129
INJECTOR CUT OUT
For example on the NEF engine, the numbers written in red are the
injector numbers according to their physical position in the engine.
The injector numbers are determined by counting from the front of

the engine working towards the rear (pump drive). Cylinder 1 would
be at the accessory side and cylinder 6 would be at the pump drive
side.
130
INJECTOR CUT OUT
To explain this further, if the firing order for a NEF engine is

1-5-3-6-2-4, the first cylinder to fire in the order is cyl. 1. Then
second cylinder to fire in the order is cyl. 5, the third cylinder to fire
in the order is cyl. 3, the fourth cylinder to fire in the order is cyl. 6,
the fifth cylinder to fire in the order is cyl. 2, and the sixth cylinder
to fire in the order is cyl. 4. This is done like this because the firing
order of the engines will be different between engine families, so
no labels are used except for the order in which the cylinders fire.
131
3.12 PARAMETER GROUPING & GRAPHING
From the Main Menu use the arrow (circled) to scroll to page 2 in
the DIAGNOSIS menu. Then click on PARAMETERS READING
and click on the green arrows
132
PARAMETER GROUPING & GRAPHING
A list of engine parameters will pop up. There are 13 pages of parameters.
Use the page arrows to scroll to the view desired parameter or proceed to
the following pages to group and graph parameters.
133
Parameters may be grouped and monitored to help in diagnosing
specific machine faults. A maximum of 10 parameters may be added
to a specific group. In the parameters screen click on Groups.
134
A Groups window will pop up. Click on Create to build a specific
parameter group. There are already some default groups and the
new group you create will be added to this list.
135
A NEW window will pop up. Type in a name for the group that is
appropriate for the type of fault. In this example the new group is named
Fuel Injection Test. Once the name is entered click on the green tick.
136
A Modify window will pop up. Click on the desired parameters and
then click on the ‘right arrow’ to add it to your list. Note: The
parameters chosen should be relevant to the fault being diagnosed.
137
The parameter selected will now appear in the new group list (Fuel
Injection Test) that was created. Continue to add up to 10
parameters.
138
Once all the required parameters have been selected click on Save
and then close the window by clicking on the red X.
Click
139
In the Groups menu scroll to the new Group that was just set up.
Click on the group (Fuel Injection Test) and then click on
Select(circled).
140
The new group window will pop up. Click on Parameter Acquisition
(circled).
141
A notes window will pop up. Type in a note if applicable and then
click on the green tick.
142
A settings window will pop up. The duration is the length of the recording and this
can be set from 5 seconds to 30 minutes. The sampling selection sets how often
the parameter will be measured within the recorded time and can be set from
every 100mS to 1 second. Once set click on the green flag to start the recording.
143
The recording will begin with progress shown by the blue line.
Note: The green flag that was used to start the recording has turned to an X.
Recording
time line
144
When the recording has stopped the green flag on the left of the settings
screen will re-appear. To view the graph click on the graph icon (circled).
145
To save the parameter recording click on the Save File icon(circled).
146
Click on the Save File icon(circled) and save as an Excel file.
147
Name the file(Fuel Injection Test in this example) as per the type of test,
save the file to the desired location(desktop) and then click on Save
148
3.13 FLAP VALVE TEST
From the main menu click on TEST and then FLAP VALVE TEST.
Ensure the key is on but the engine is NOT running.
149
FLAP VALVE TEST
An ATTENTION screen will pop-up. Click on he green tick.
150
FLAP VALVE TEST
A Flap Valve Test description window will pop up, click on the green
tick.
151
FLAP VALVE TEST
Click on FLAP and then on FLAP VALVE TEST.
152
FLAP VALVE TEST
Ensure the key is ON and click on the green tick.
153
FLAP VALVE TEST
A Please wait screen will pop up. It will take a few moments for the
test to begin.
154
FLAP VALVE TEST
The following graph will be produced by the test.
155
3.14 DEF Supply Module Flushing Test
CHANGING DEF DOSING MODULE
FILTER, DEF FLUSHING TEST
TOOLS REQUIRED
 27 mm (1 1/16 in) wrench
 Container to catch DEF and flushing water
 Clean distilled/demineralized water
 1 liter (0.25 US gal) plastic water bottle with hose attached*
 Laptop computer with Tigercat by FPT E.A.SY. software to run UDST test*
 PT-Box*
IMPORTANT! Do not contaminate the DEF when performing maintenance on

the system as this may cause costly damage to SCR system components and
affect the proper operation of the after-treatment system and the engine.
*Items required if performing a DEF flushing test and UDST

147
DEF Supply Module Flushing Test
REMOVE DEF DOSING MODULE FILTER
1. Park the machine on level ground with the attachment(s) resting firmly on the
ground. Refer to the Machine Operator/Service Manual.
2. Make sure the engine is at operating temperature.
3. Turn OFF the engine.
4. Remove the ignition key.
5. Wipe clean the area around the supply module and filter including the supply
module ports with particular attention to the inlet port and filter cap to avoid
introducing contamination into the filter housing while performing this
procedure.
6. Place container below to catch the spills.

148
7. Turn the filter cover counterclockwise

to remove from the supply module.
Use a 27 mm (1 1/16 in) wrench.
8. Remove the equalizing element and

note the color of the filter inside (black
or grey).
9. Find the filter removal tool provided

with the replacement parts select the
correct edge BLACK (B) for black
filters or GREY (G) for grey filters
149
10. Insert the tool edge completely until a

click is felt or heard.
11. Pull out the filter, using a tool in the

slot on the filter removal tool if
required.
12. Clean surfaces with

distilled/demineralized water only to
avoid DEF contamination. Check the
area around the filter for cracks. If
cracks are found the supply module
must be replaced.
13. Thoroughly clean the filter cover to

avoid introducing contamination
150
DEF FLUSHING TEST
1. Disconnect the DEF hose from the inlet port of DEF supply module.
2. Fill the plastic bottle with distilled/ demineralized water.
3. Connect the water bottle hose to the inlet port of the DEF supply module.
151
4. Raise the water bottle above the DEF

supply module.
5. A small amount of water will flow through

the supply module and out the bottom
where the filter has been removed.
6. With the aid of an assistant run a UDST

from the laptop computer. Refer to FPT
Engine Troubleshooting Manual for UDST
information.
7. Distilled water will be drawn from the bottle

and flushed through the DEF supply
module. Suction may begin to collapse the
bottle and water flow out the bottom of the
module will increase.
152
8. The results of the UDST will show a flat line for DEF pressure (red
line) because the pump cannot build pressure without the filter in
place.
9. Repeat the UDST test a second time to ensure the supply module
is thoroughly flushed and working correctly.
10. When the UDST flushing procedure has been performed twice
successfully remove the bottle and hose.
11. Reinstall the DEF module inlet hose.
153
INSTALL THE NEW FILTER
1. Install the new filter. Lubricate the o-rings

on the filter with clean DEF solution for
easy installation.
2. Install the new equalizing element.
NOTE: The equalizing element must be

replaced with each filter change.
3. Reinstall the clean filter cover, tighten to 20

Nm (15 lb-ft). Use a 27 mm (1 1/16 in)
wrench.
4. Check that all personnel are clear of the

machine before starting the engine.
154
5. Insert the ignition key and turn to the RUN position.
6. Sound horn to warn personnel of machine start-up.
7. Start the engine.
8. Check for leaks.
9. Turn OFF the engine.
155
4. ECM – EDC 7 UC31- K Line
Tier 4 Interim Engine ECU Connection
4.1 Connecting to Engine ECU on T4i
Open E.a.s.y, a USER ACCOUNT CONTROL window will pop up,

click on yes and then when the E.A.S.Y window pops up click on
ACCEPT and then on the green tick icon.
166
Connecting to Engine ECU on T4i
Click on ELECTRONIC SYSTEM ENGINE and then on the green

arrows.
167
A SELECT ECI window will pop up, click on the green tick.
168
Click on ENGINE, then click on ECM-EDC 7 UC31-K LINE and

then click on the green arrows.
169
When the ATTENTION window pops up click on the green tick

icon.
170
When the IGNITION KEY window pops up click on MANUAL.
171
When the next IGNITION KEY window pops up click on the green
tick icon.
172
When the ENGINE DATA window pops up check there is a 15 digit

ENGINE ID number and then click on SAVE AND EXIT.
173
When the ATTENTION window pops up click on the green tick.
174
4.2 Reading and Saving Fault Codes
This is the main menu page.

To read the stored fault codes click on FAULTS MEMORY
READING and then on the green arrows.
175
Reading and Saving Fault Codes
To save the stored fault codes click on file icon at the bottom of the
screen.
176
Click on print icon in the fault code screen.
177
When the Print Options window pops up select Microsoft XPS

178
1. Select a location to save (desktop) and change the file name to

the current date (yymmdd), machine s/n and Engine ECU Fault
Codes (eg. 140226 6304002 Engine ECU Fault Codes)
2. Select ‘Save’
179
4.3 Clearing Engine Fault Codes
When in the Engine Fault Codes screen click on CANCEL FAULTS

MEMORY.
180
Clearing Engine Fault Codes
A window will pop up to confirm the cancel faults memory. Click on

the green tick.
181
Clearing Engine Fault Codes
A window will pop up to show Faults memory deleted. Click on the

green tick. The engine fault codes are now cleared.
Note: Only intermittent codes will be cleared. Present (active) faults
will remain.
182
4.4 Reading and Saving Log File (Data Stored)
On the Main Menu page click on the arrow to enable access to the
2nd Diagnosis page.
Then click on DATE STORED and the green arrows.
183
Reading and Saving Log File (Data Stored)
An Ignition window will pop up. Click on the green tick.
184
The DATA SAVED window will pop up. To save the file click on the
print icon.
185
example) and then name the file to include the current date (yymmdd),
machine serial number and Data Stored, then select save.
186
4.5 Counters Reset
If a machine detects 3 consecutive aftertreatment faults then Severe

Inducement (Engine Derate) is activated. Once the fault is repaired a
COUNTERS RESET is necessary to cancel the Severe Inducement. From
the Main Menu select COUNTERS RESET and click on the green arrows.
187
Counters Reset
188
Counters Reset
Click the COUNTERS RESET box and then click on the green
arrows.
189
Counters Reset
Click the MANUAL box.
190
Counters Reset
Ensure the ignition key is on and click on the green tick.
191
Counters Reset
Turn the key OFF and then click on the green tick.
192
Counters Reset
Click on the COUNTERS RESET box
193
Counters Reset
Turn the ignition key ON and click on the green tick.
194
Counters Reset
Turn the key OFF and then click on the green tick.
195
Counters Reset
A window should pop up showing “OPERATION SUCCESSFULLY

CARRIED OUT”. Click on the green tick. The counters reset is now
complete.
196
4.6 Reading Engine Parameters
From the Main Menu use the arrow (circled) to scroll to page 2 in
the DIAGNOSIS menu. Then click on PARAMETERS READING
and click on the green arrows
197
Reading Engine Parameters
A list of engine parameters will pop up. There are 7 pages of

parameters. Use the page arrows to scroll to the desired
parameter.
198
Grouping Parameters for Diagnostics
Parameters may be grouped and monitored to help in diagnosing

specific machine faults. A maximum of 10 parameters may be
added to a specific group. In the parameters screen click on
Groups.
199
A Groups window will pop up. Click on Create to build a specific
parameter group. There are already some default groups and the
new group you create will be added to this list.
200
A NEW window will pop up. Type in a name for the group that is
appropriate for the type of fault. In this example the new group is named
T234B Surging Fault. Once the name is entered click on the green tick.
201
A Modify window will pop up. Click on the desired parameters and
then click on the ‘right arrow’ to add it to your list. Note: The
parameters chosen should be relevant to the fault being diagnosed.
202
After you click on the ‘right arrow’ the parameter will be added to your group.
Scroll through the parameter pages using the arrow (circled) to select the desired
parameters. If you wish to remove a parameter from your group click on the ‘left
arrow’ and to change the order of your group parameters click on a parameter in
the group and use the up and down arrows to move to the desired position.
203
Once you have finished adding(max of 10) to your list click on SAVE
and then close this window by clicking on the red X.
204
Recording Parameter Group
You are now back in the Groups window. Scroll to the last page of the
group pages using the arrow(circled) then click on the group you
have saved and then click on Select.
205
Your parameter group will pop up along with a settings window. The duration is the
length of the recording and this can be set from 5 seconds to 30 minutes. The
sampling selection sets how often the parameter will be measured within the recorded
time and can be set from every 100mS to 1 second. Once set click on the green flag.
206
The recording will begin with progress shown by the blue line. Once the
recording has finished click on the graph icon (circled). The example of the
recording below will run for 30 seconds with sampling done every 100mS.
Recordi
ng time
line
207
Graph Parameter Group (No Fault)
The graph shown below has no fault. Note the Coolant Temperature Graph in Green.
The next slide will show a fault related to the coolant sensor. The various parameters
are color coded.
Parameter
reading
Parameter
Parameter range
name
208
Graph Parameter Group (With Fault)
The graph shown below has a fault. Note the change in the Coolant
Temperature Graph in Green and the change in the range. The range will
automatically adjust to the range in values that are detected.
Parameter
reading
Parameter Parameter
name range
209
Saving Parameter Group Graph
To save a copy of the graph click on the Screen icon, (circled) a printer screen
will pop up and ensure Microsoft XPS Document Writer is selected and then
click on OK.
210
Saving Parameter Group Graph
Name the file and choose a location (desktop shown below) to save the file
and then click on Save
211
Saving Parameters to Excel File
Click on the file icon(circled)
212
A Report window will pop up. Click on the file icon(circled) and then
select Excel.
213
Name the file and choose a location (desktop shown below) to save the file
and then click on Save
214
4.7 Active Diagnosis
The ACTIVE DIAGNOSTICS menu provides a number of diagnostic tests.

From the Engine ECU main menu click on ACTIVE DIAGNOSIS and then click
on the green arrows.
215
216
When the Ignition Key window pops up click on the green tick
217
After a few moments the ENGINE TYPE SELECTION

window will appear. When the ENGINE TYPE SELECTION
window pops up click F4HE9 (4 or 6 CYLINDERS)
Select 4
or 6 Cyl
218
1.Select from
these
available tests
• Three available tests – ENGINE SPEED, RAIL PRESSURE, and INJECTOR CUTOUT
• ENGINE BRAKE not applicable to Tigercat applications
2. Select
219
4.7 Active Diagnosis – Engine Speed
ENGINE SPEED
• Allows you to monitor actual engine rpm’s or increase/decrease the rpm’s as needed
• Selecting the STOP button will shutdown the engine
220
4.7 Active Diagnosis – Rail Pressure
RAIL PRESSURE
• Allows you to monitor fuel RAIL PRESSURE or increase/decrease the pressure as desired
• Second gauge available to view the reaction of engine rpm’s
221
4.7 Active Diagnosis – Injector Cut Out
INJECTOR CUTOUT
• Allows you to simultaneously monitor Temperature, Charging Voltage, Fuel Consumption, Engine
RPM’s and Rail Pressure while disabling one Fuel Injector at a time.
222
5. Denoxtronic 2
Tier 4 Interim DCU Connection
5.1 Connecting to Dosing Supply Unit(DCU)
Open E.a.s.y, a USER ACCOUNT CONTROL window will pop up,

click on yes and then when the E.A.S.Y window pops up click on
ACCEPT and then on the green tick icon.
224
Connecting to DCU
Click on ELECTRONIC SYSTEM ENGINE and then on the green

arrows.
225
Connecting to DCU
A SELECT ECI window will pop up, click on the green tick.
226
Connecting to DCU
Click on ENGINE, then click on DENOXTRONIC 2 and then click

on the green arrows.
The next window may take a few moments to appear.
227
Connecting to DCU

icon.
228
Connecting to DCU
When the IGNITION KEY window pops up click on MANUAL.
229
Connecting to DCU
When the next IGNITION KEY window pops up click on the green
tick.
230
Connecting to DCU
When the ENGINE DATA window pops up check there is a 15 digit

ENGINE ID number and then click on SAVE AND EXIT.
231
Connecting to DCU
When the ATTENTION window pops up click on the green tick.
232
5.2 Reading and Saving DCU Fault Codes
This is the main menu page.
To read the stored fault codes click on FAULTS MEMORY
READING and then on the green arrows.
233
Reading and Saving DCU Fault Codes
To save the stored fault codes click on file icon (circled) at the
bottom of the screen.
234
Wait until the faults appear in the screen and then click on print
icon in the fault code screen.
235
When the Print Options window pops up select Microsoft XPS
236
Name the file as per the Machine serial number and Supply
Module Fault Codes and save to a location (USB stick shown
below) of your choice.
237
5.3 UDST Test (Urea Dosing System Test)
From the main menu screen (still in DENOXTRONIC 2 System)
select UDST and click on the green arrows.
238
UDST Test
An ATTENTION window will pop up, click on the green tick icon.
239
UDST Test
A UDST window will pop up, click on the green tick icon.
240
UDST Test
A UDST window will pop up, click on RUN and then UDST (AdBlue
Dosing System Test).
241
UDST Test
An Ignition Key window will pop up, click on the green tick icon.
242
UDST Test
A warning window will pop up, click on the green tick icon.
Note: Abide warning, as two consecutive tests will saturate the
SCR.
243
UDST Test
The UDST graph screen will appear. After a few moments the UDST
test will begin. The UDST will take about 1 ½ minutes to complete.
244
Saving UDST Test Results
A system report window will appear. To save this report click on the
print icon.
245
Name the file as per the Machine serial number and UDST Report
and save to a location of your choice.(USB stick shown below).
246
The system report window will appear again. Click on VIEW

DIAGRAM and then UDST.
247
To save this graph click on the print icon.
248
Name the file as per the Machine Serial number and UDST Graph
and save to a location of your choice. (USB stick shown below)
249
5.4 Dosing Valve Test
To perform the Dosing Valve Test the Dosing Valve (injector) MUST
be removed and placed in a measuring cup. Once in the UDST
screen click on RUN and then DOSING VALVE CHECK.
250
Dosing Valve Test
A Dosing Valve Check table will pop up. Mode 2 is to be used.

Mode 2 in this table will show the amount of DEF fluid (grams)
injected during the test. The actual volume of DEF fluid that Mode
2 should deliver is 43 ml or 1.45 fl oz. Click on the green arrow.
251
Dosing Valve Test
A Dosing Valve Check selection table will pop up. Click on MODE 2
(20g – 18s) and then click on the bottom right box (almost
obscured) to initiate the test.
252
Dosing Valve Test
An Ignition Key window will pop up, click on the green tick icon.
253
Dosing Valve Test
The test will run for approximately 3 minutes. Observe the spray
pattern of the injector as the test runs.
254
Dosing Valve Test
Once the test is complete an ignition key window will pop up. Click
on the green tick.
255
Saving Dosing Valve Test Graph
Click on the print icon to save the graph.
256
Saving Dosing Valve Test Graph
Name the file as per the Machine Serial number and Dosing Valve
Check and save to a location of your choice. ( USB stick shown
below) Measure the volume of fluid in the injector container. It
should be 43 ml/1.45floz (+/- 10%).
257

FPT Engine Troubleshooting Manual Rev1.1

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

FPT Engine Troubleshooting Manual Rev1.1

Uploaded by

Copyright:

Available Formats

1

FPT Engine Troubleshooting Manual

Pre Heater Resistance 105-106

Prior to attempting to connect the tablet or laptop to a machine

The PT Box is the interface that allows the Engine ECU to

Connect to the machine in this order.

NOTE: When using the program there is sometimes a delay after

PT-Box to Diagnostic Port (2 Cables)

1. Select E.A.S.Y Icon on desktop. A window

2. Select ‘Accept’ 3. Select Checkmar

Click on Electronic System Engine and then click on the

Click on the green tick in the bottom right.

Select the appropriate ECU to be viewed. Select ECM-EDC17CV41

Click on the green tick in the ATTENTION box.

Click on MANUAL in the IGNITION KEY box.

Click on the green tick box.

When the ENGINE DATA window pops up check there is a 15

Click on the green tick.

IDENTIFICATION CODE READING – Not used

FAULTS MEMORY READING

FLAP VALVE TEST

UDST (UREA DOSING SYSTEM TEST)

FORCED REGENERATION: NORMAL MODE

INDUCEMENT COUNTERS RESET FOR SERVICE

INDUCEMENT EDC17CV41 EURO VI

To access the engine fault codes click on FAULTS MEMORY READING

To show the next code click on the arrow(circled) to scroll to the

Click on the printer icon at the bottom of the screen. A printer

Select a location where you want to save the file(desktop shown in

To access the trip recorder click on DIAGNOSIS and then click on

Use the arrows to scroll up or down to view the stored data.

A printer choice window will pop up. Select Microsoft XPS

If a machine detects 3 consecutive aftertreatment faults then Severe

Click on INDUCEMENT COUNTER RESET FOR SERVICE and

An ATTENTION window will pop up. Click on the green tick.

Click on INDUCEMENT COUNTER RESET FOR SERVICE and

Click on the INDUCEMENT COUNTER RESET FOR SERVICE

Figure 1 – DEF defrost mode error

REQUIRED ACTION: Validate DEF tank temperature before starting any

1. A minimum DEF tank temperature of 22° Celsius (72° Fahrenheit) is needed

3. Once the DEF tank temp is at required temperature the after-treatment

Before performing the UDST the following criteria must be met:

A warning window will appear, click the green tick to continue.

Ensure the ignition key is on and click on the green tick to

If the UDST test is OK the following screen will appear.

An information screen will appear, click on green tick to continue.

A warning screen will appear, ensure engine is not running and

An Ignition Key screen will appear, click on green tick to continue.

This screen will appear, wait until the test begins.

Click on UDLC and in the dropdown box click on LOAD REPORT.

Click on file just created (identified by date) and then click on

The UDLC report will appear.

Click on UDLC and in the dropdown box click on SEE DIAGRAM

Before perform the UDVC the following criteria must be met:

WARNING: The following test pressurizes the

A DOSING VALVE CHECK screen will appear, click on the green

Ensure the ignition switch is on and click on the green tick to

A Connection Opening in progress window will appear, wait until

Another window will appear, wait until the test starts.

Before perform the UDPC the following criteria must be met:

WARNING: The following test pressurizes the

A warning screen will appear, ensure engine is not running and

An ATTENTION window will pop up. Click on the green tick.