Overview
| CODE | REASON | EFFECT |
| Fault Code: 3649 PID: SPN: 5024 FMI: 10/10 LAMP: Amber SRT: |
The aftertreatment intake NOx sensor heater is unable to maintain its normal operating temperature.
|
None on performance. |
Circuit Description
The aftertreatment intake NOx (nitrogen oxides) sensor is a smart device and communicates with the engine control module (ECM) via the J1939 data link. The aftertreatment intake NOx sensor performs internal diagnostics and reports malfunctions back to the primary ECM using the J1939 data link. The NOx sensor is permanently attached to the NOx control module. They are serviced as a single component and can not be replaced individually. The aftertreatment intake NOx sensor is used to measure the NOx emissions at the intake of the aftertreatment system.
Component Location
The aftertreatment intake NOx sensor is mounted on the engine near the turbocharger turbine outlet.
Conditions for Running the Diagnostics
This diagnostic runs when the aftertreatment diesel oxidation catalyst intake temperature sensor has been above a calibrated value for a calibrated time while the engine is running.
Conditions for Setting the Fault Codes
The Engine Control Module (ECM) detected the NOx sensor heater was unable to maintain its normal operating temperature.
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
- For On-Board Diagnostics (OBD) engines, the ECM will extinguish the Malfunction Indicator Lamp (MIL) after three consecutive trips where the diagnostic runs and passes.
- 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:
- Malfunctioning or damaged aftertreatment intake NOx sensor.
Troubleshooting Summary
- Check for primary fault codes
- Aftertreatment intake NOx sensor voltage check
- Aftertreatment power relay voltage check
- Aftertreatment power relay resistance check
- Aftertreatment intake NOx sensor circuit check
- Aftertreatment power relay circuit check
- ECM calibration revision history check
- Aftertreatment intake NOx sensor is malfunctioning
Solution: S00000293
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 NOx: 1885, 3232, 3682
- Aftertreatment DOC: 3313, 3314, 3315
Linked Solutions
- None
Repair
- Perform a search on the appropriate fault codes.
Validation
- None
Solution: S00010492
Verification
Conditions
- Turn keyswitch OFF.
- Disconnect the aftertreatment intake NOx sensor from the engine wiring harness.
Action
- Inspect the pins and connectors for damage.
- Turn keyswitch ON.
- Measure the voltage between the aftertreatment intake NOx sensor SUPPLY pin and the aftertreatment intake NOx sensor RETURN pin at the sensor connector of the engine wiring harness.
- Refer to the circuit diagram or wiring diagram for connector pin identification.
Specification
- Proceed to the Linked Solutions section if the voltage is not within the following specification of battery voltage: 1 VDC
Linked Solutions
- Aftertreatment power relay voltage check
- Aftertreatment power relay resistance check
- Aftertreatment intake NOx sensor circuit check
- Aftertreatment power relay circuit check
Repair
- No additional action is required for this solution.
Validation
- None
Solution: S00010303
Verification
Conditions
- Turn keyswitch OFF.
- Disconnect the aftertreatment power relay from the OEM wiring harness.
Action
- Inspect the pins and connectors for damage.
- Turn keyswitch ON.
- Measure the voltage between the aftertreatment power relay battery voltage SUPPLY pin in the aftertreatment power relay connector of the OEM wiring harness and ground.
- Refer to the circuit diagram or wiring diagram for connector pin identification.
Specification
- A malfunctioning fuse or OEM wiring harness has been detected if the voltage is not within the following specification of battery voltage: 1 VDC
Linked Solutions
- None
Repair
Repair or replace only the components that were found to be out of specification.
- Replace the fuse.
- Repair or replace the OEM wiring harness.
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: S00010305
Verification
Conditions
- Turn keyswitch OFF.
- Disconnect the aftertreatment power relay from the OEM wiring harness.
Action
- Inspect the pins and connectors for damage.
- Check the relay.
- Refer to the circuit diagram or wiring diagram for connector pin identification.
Specification
- If the relay does not meet specification, then a malfunctioning relay has been detected.
Linked Solutions
- None
Repair
- Replace the aftertreatment power relay.
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.
Solution: S00010514
Verification
Conditions
- Turn keyswitch OFF.
- Disconnect the aftertreatment power relay from the OEM wiring harness.
- Disconnect the aftertreatment intake NOx sensor from the engine wiring harness.
Action
- Inspect the pins and connectors for damage.
- Measure the resistance between the aftertreatment power relay SUPPLY pin at the aftertreatment power relay connector of the OEM wiring harness and the aftertreatment power relay SUPPLY pin at the engine wiring harness aftertreatment intake NOx sensor connector.
- Refer to the circuit diagram or wiring diagram for connector pin identification.
Specification
- A malfunctioning OEM wiring harness or engine wiring harness has been detected if the resistance is greater than the following specification: 10 Ω
Linked Solutions
- None
Repair
Repair or replace only the components that were found to be out of specification.
- Troubleshoot the OEM wiring harness, engine wiring harness, and all interconnects.
- Repair or replace the OEM wiring harness.
- Repair or replace the engine wiring harness.
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: S00010368
Verification
Conditions
- Turn keyswitch OFF.
- Disconnect the aftertreatment power relay from the OEM wiring harness.
- Disconnect the engine wiring harness connector from the ECM.
Action
- Inspect the pins and connectors for damage.
- Measure the resistance between the aftertreatment power relay CONTROL pin at the aftertreatment power relay connector of the OEM wiring harness and the aftertreatment power relay CONTROL pin at the engine wiring harness ECM connector.
- Refer to the circuit diagram or wiring diagram for connector pin identification.
Specification
- A malfunctioning OEM wiring harness or engine wiring harness has been detected if the resistance is greater than the following specification: 10 Ω
Linked Solutions
- None
Repair
Repair or replace only the components that were found to be out of specification.
- Troubleshoot the OEM wiring harness, engine wiring harness, and all interconnects.
- Repair or replace the OEM wiring harness.
- Repair or replace the engine wiring harness.
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.
Solution: S00007913
Verification
Conditions
- Turn keyswitch ON.
- Connect the recommended Cummins® electronic service tool or equivalent.
Action
- Verify all preceding solution verifications for this fault code have been performed.
- Use the recommended Cummins® electronic service tool or equivalent to read the fault codes.
Specification
- If the fault code is active or has more than one inactive count within the last 25 engine operating hours, then a malfunctioning aftertreatment intake NOx sensor has been detected.
Linked Solutions
- None
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.