Overview
| CODE | REASON | EFFECT |
| Fault Code: 2638 PID: S380 SPN: 5298 FMI: 1/17 LAMP: None SRT: |
The temperature increase across the aftertreatment diesel oxidation catalyst is lower than expected.
|
May cause frequent aftertreatment regeneration.
|
Circuit Description
The aftertreatment diesel particulate filter temperature sensor module is a smart device that communicates with the engine control module via the J1939 data link. The aftertreatment diesel partculate filter temperature sensor module performs its own internal diagnostics and reports malfunctions back to the engine control module using the J1939 data link. The aftertreatment diesel particulate filter temperature sensor module is used to measure the aftertreatment diesel oxidation catalyst intake temperature, aftertreatment diesel particulate filter intake temperature, and aftertreatment diesel particulate filter outlet temperature. The temperature probes are permanently attached to the aftertreatment diesel particulate filter temperature sensor module and can not be replaced individually.
Component Location
The aftertreatment diesel oxidation catalyst is located in the exhaust system. The location of the catalyst can vary, depending on the original equipment manufacturer (OEM). Refer to the OEM service manual.
Conditions for Running the Diagnostics
This diagnostic runs continuously when the engine is running and active regeneration of the aftertreatment diesel particulate filter is occurring.
Conditions for Setting the Fault Codes
The Engine Control Module (ECM) calculated the DOC efficiency was less than required to successfully complete a regeneration.
Action Taken When the Fault Code is Active
- The ECM illuminates the amber CHECK ENGINE lamp and/or the malfunction indicator lamp (MIL) immediately when the diagnostic runs and fails.
Conditions for Clearing the Fault Code
- This diagnostic can not be run in the shop environment.
- The “Reset All Faults” command in the recommended Cummins® electronic service tool or equivalent can be used to clear active and inactive faults, as well as extinguish the MIL for OBD applications.
Shop Talk
Possible causes of this fault code include:
A malfunctioning diesel oxidation catalyst
A malfunctioning aftertreatment fuel injector
Troubleshooting Summary
- Check for primary fault codes
- Aftertreatment DPF Permit Switch Status is in the OFF position
- Aftertreatment exhaust system leaks
- Aftertreatment temperature sensor stuck in-range
- Aftertreatment DOC temperature limited by ambient temperature
- Turbocharger exhaust is leaking oil into the aftertreatment system
- Aftertreatment DOC is malfunctioning
- ECM calibration revision history check
Solution: S00002466
Verification
Conditions
- Turn keyswitch ON.
- Connect the recommended Cummins® electronic service tool or equivalent.
Action
- Use the recommended Cummins® electronic service tool or equivalent to read the fault codes.
Specification
Before troubleshooting this fault code, troubleshoot any fault code that is active or has more than one inactive count within the last 25 engine operating hours from the following list:
- Aftertreatment regeneration: 2777, 6416
- Aftertreatment DOC: 3251, 3313, 3314, 3315
- Aftertreatment DPF: 1879, 1881, 1883, 1921, 1922, 1981, 1993, 2639, 3133, 3134, 3135, 3168, 3253, 3254, 3255, 3256, 3311, 3312, 3316, 3317, 3318, 3319, 3321, 3322, 3375, 3376, 3396, 4151, 4158, 4161, 4162, 4163, 4259, 5616, 5716
- Turbocharger: 595, 687, 691, 692, 693, 1898, 1962, 2198, 2288, 2387, 2449, 2634, 2636, 3616, 4956, 4957, 5177
- EGR: 1228, 1866, 1867, 1896, 1961, 2272, 2273, 2274, 2349, 2353, 2375, 2376, 2961, 2962, 3342, 3382, 3383, 4485
- Fuel: 271, 272, 451, 452, 553, 559, 2311, 2372, 3727, 3741, 5384, 5385
- Aftertreatment diesel exhaust fluid dosing unit: 3167
Linked Solutions
- None
Repair
- Perform a search on the appropriate fault codes.
Validation
- None
Solution: S00001026
Verification
Conditions
- Turn keyswitch OFF.
Action
- Visually verify the Aftertreatment DPF Permit Switch is in the ON position.
Specification
- If the Aftertreatment DPF Permit Switch is in the ON position, then proceed to the next solution.
- If the Aftertreatment DPF Permit Switch is not in the ON position, then proceed to the Repair section.
- If there is not an Aftertreatment DPF Permit Switch on the dash, then an incorrect parameter setting has been determined. Proceed to the Repair section.
Linked Solutions
- None
Repair
Repair or replace only the components that were found to be out of specification.
- Turn the Aftertreatment DPF Permit Switch Status to the ON position.
- Adjust the features and parameters to the correct settings.
Refer to OEM Service Manual
Validation
- Connect all components
- Connect the recommended Cummins® electronic service tool or equivalent.
- Disable the fault code.
- Operate the engine within the “Conditions for Clearing the Fault Code” found in the Overview section of the troubleshooting procedure.
- Verify that the fault code is no longer active.
- Check ECM Calibration Revision History
- Use the recommended Cummins® electronic service tool or equivalent to find the current ECM code and revision number in the ECM.
- Compare the ECM code and revision number in the ECM to the calibration revisions listed in the ECM Calibration Revision History Database for applicable changes related to this fault code.
- Refer to ECM Calibration Revision History Database.
- Perform the aftertreatment stationary regeneration.
Solution: S00001008
Verification
Conditions
- Engine running.
Action
- Visually inspect for leaks in the exhaust manifold to head.
- Visually inspect for leaks from the turbocharger to exhaust manifold.
- Visually inspect for leaks in the exhaust plumbing between the turbocharger outlet and the Aftertreatment DOC intake connection.
- Visually inspect the exhaust piping for leaks, cracks, and loose connections.
- Inspect for leaks at the aftertreatment DOC housing, sensor ports and connection points.
- Visually inspect the aftertreatment and SCR components for exhaust leaks.
Specification
- If there is any damage or leaks found in the exhaust system, then proceed to the Repair section.
Linked Solutions
- None
Repair
Repair or replace only the components that were found to be out of specification.
- Replace the exhaust manifold.
- Repair or replace the exhaust plumbing.
Refer to OEM Service Manual
- Replace aftertreatment DOC.
- Replace the aftertreatment diesel particulate filter.
- Replace the aftertreatment SCR Catalyst.
Validation
- Connect all components
- Connect the recommended Cummins® electronic service tool or equivalent.
- Disable the fault code.
- Operate the engine within the “Conditions for Clearing the Fault Code” found in the Overview section of the troubleshooting procedure.
- Verify that the fault code is no longer active.
- Check ECM Calibration Revision History
- Use the recommended Cummins® electronic service tool or equivalent to find the current ECM code and revision number in the ECM.
- Compare the ECM code and revision number in the ECM to the calibration revisions listed in the ECM Calibration Revision History Database for applicable changes related to this fault code.
- Refer to ECM Calibration Revision History Database.
Solution: S00000338
Verification
Conditions
- Connect all components.
- Turn keyswitch ON.
- Connect the recommended Cummins® electronic service tool or equivalent.
- Start the engine.
Action
- Run the engine at high idle for the following minutes: 10
- Use the recommended Cummins® electronic service tool or equivalent.
Monitor the following parameters:
- Aftertreatment diesel oxidation catalyst intake temperature
- Aftertreatment diesel particulate filter intake temperature
- Aftertreatment diesel particulate filter outlet temperature
Specification
- A malfunctioning aftertreatment exhaust gas temperature sensor has been detected if each sensor is not within the following specification of the others: 24 C [43 F]
Linked Solutions
- None
Repair
Repair or replace only the components that were found to be out of specification.
- Replace the aftertreatment exhaust gas temperature sensor module.
Validation
- Connect all components
- Connect the recommended Cummins® electronic service tool or equivalent.
- Disable the fault code.
- Operate the engine within the “Conditions for Clearing the Fault Code” found in the Overview section of the troubleshooting procedure.
- Verify that the fault code is no longer active.
- Check ECM Calibration Revision History
- Use the recommended Cummins® electronic service tool or equivalent to find the current ECM code and revision number in the ECM.
- Compare the ECM code and revision number in the ECM to the calibration revisions listed in the ECM Calibration Revision History Database for applicable changes related to this fault code.
- Refer to ECM Calibration Revision History Database.
Solution: S00003390
Verification
Conditions
- Turn keyswitch ON.
- Connect the recommended Cummins® electronic service tool or equivalent.
Action
- Use the recommended Cummins® electronic service tool or equivalent.
- Monitor the OEM ambient air temperature sensor.
- Verify the ambient temperature.
Specification
- A stationary regeneration will not complete due to the cold temperatures preventing the DOC from reaching minimum required temperature If the ambient temperature is below the following specification: -18 C [0 F].
Linked Solutions
- None
Repair
- Move vehicle to a safe location where the ambient temperature is above the following specification: -18 C [0 F].
- Perform the Aftertreatment Stationary Regeneration procedure.
Validation
- Connect all components
- Connect the recommended Cummins® electronic service tool or equivalent.
- Disable the fault code.
- Operate the engine within the “Conditions for Clearing the Fault Code” found in the Overview section of the troubleshooting procedure.
- Verify that the fault code is no longer active.
- Check ECM Calibration Revision History
- Use the recommended Cummins® electronic service tool or equivalent to find the current ECM code and revision number in the ECM.
- Compare the ECM code and revision number in the ECM to the calibration revisions listed in the ECM Calibration Revision History Database for applicable changes related to this fault code.
- Refer to ECM Calibration Revision History Database.
Solution: S00000655
Verification
Conditions
- Turn keyswitch OFF.
- Remove the exhaust piping from the turbocharger outlet.
Action
- Inspect for any fluids.
- Visually inspect the turbocharger exhaust outlet for signs of oil or fuel.
- Perform the Snap Acceleration Test – Aftertreatment Disconnected.
Specification
- If lubricating engine oil contamination is found in the turbocharger exhaust outlet, then reset the search to oil consumption internal.
- If excessive black smoke is detected, then reset the search to black smoke.
Linked Solutions
- None
Repair
- No additional action is required for this solution.
Validation
- None
Solution: S00000761
Verification
Conditions
- Turn keyswitch OFF.
Action
- Visually inspect for the presence of the aftertreatment DOC.
- Inspect the inlet face of the aftertreatment DOC for reuse.
Refer to Service Bulletin 4021600
- Inspect for cracks in the aftertreatment DOC cell walls.
Refer to Service Bulletin 4021600
- Inspect for soot or oil plugging the front face of the catalyst
Specification
- If plugging or damage is found, then proceed to the Repair section.
- If the face of the aftertreatment diesel oxidation catalyst is cracked or damaged, then proceed to Repair section.
Linked Solutions
- None
Repair
Repair or replace only the components that were found to be out of specification.
- If the face of the aftertreatment DOC is plugged, then clean the aftertreatment DOC.
- If the face of the aftertreatment DOC is cracked or damaged, then replace the aftertreatment DOC.
Validation
- Connect all components
- Connect the recommended Cummins® electronic service tool or equivalent.
- Disable the fault code.
- Operate the engine within the “Conditions for Clearing the Fault Code” found in the Overview section of the troubleshooting procedure.
- Verify that the fault code is no longer active.
- Check ECM Calibration Revision History
- Use the recommended Cummins® electronic service tool or equivalent to find the current ECM code and revision number in the ECM.
- Compare the ECM code and revision number in the ECM to the calibration revisions listed in the ECM Calibration Revision History Database for applicable changes related to this fault code.
- Refer to ECM Calibration Revision History Database.
Solution: S00000443
Verification
Conditions
- Connect all components.
- Turn keyswitch ON.
- Connect the recommended Cummins® electronic service tool or equivalent.
Action
- Use the recommended Cummins® electronic service tool or equivalent to read the fault codes.
- Use the recommended Cummins® electronic service tool or equivalent to find the current ECM code and revision number in the ECM.
- Compare the ECM code and revision number in the ECM to the calibration revision listed in the ECM calibration revision history for applicable changes.
Specification
- If a calibration update for this fault code is available, the ECM calibration revision must be that revision or higher.
Linked Solutions
- None
Repair
- Prior to downloading the ECM calibration, check to see that all job images and all other troubleshooting has been documented as downloading an ECM calibration will remove the fault codes on the ECM.
- Download the updated ECM calibration code.
Validation
- Connect all components
- Connect the recommended Cummins® electronic service tool or equivalent.
- Disable the fault code.
- Operate the engine within the “Conditions for Clearing the Fault Code” found in the Overview section of the troubleshooting procedure.
- Verify that the fault code is no longer active.
- Check ECM Calibration Revision History
- Use the recommended Cummins® electronic service tool or equivalent to find the current ECM code and revision number in the ECM.
- Compare the ECM code and revision number in the ECM to the calibration revisions listed in the ECM Calibration Revision History Database for applicable changes related to this fault code.
- Refer to ECM Calibration Revision History Database.
If all steps have been completed and no root cause has been identified, then follow the technical escalation process.