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Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction

Technical Service Bulletin
Technical Service Bulletin: TSB210187
Released Date: 02-Dec-2021
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
Warranty Statement
The information in this document has no effect on present warranty coverage or repair practices, nor
does it authorize TRP or Campaign actions.

Contents
Product Affected
B6.7 CM2350 B121B (Excluding engines built in 2021)
B6.7 CM2450 B155B
ISB6.7 CM2350 B101 (Engines built in 2016 only)
ISL9 CM2350 L101 (Engines built in 2016 only)
L9 CM2350 L116B
L9 CM2350 L123B
L9 CM2450 L126B
ISX12 CM2350 X102
ISX15 CM2350 X101 (Engines built in 2016 only)
X12 CM2350 X119B
X12 CM2450 X137B
X15 CM2350 X114B
X15 CM2350 X116B
X15 CM2450 X124B
X15 CM2450 X134B
Issue
Symptom:
A combination of one or all DEF header fault code(s) 3868, 4572 and/or 4677 are logged.

Note : These ECM calibrations will only address DEF header sensor malfunctions that
are logging one or combination of DEF header fault code(s) 3868, 4572 and/or 4677.
Engine has a DEF header malfunction and replacement is not available.
Root Cause:
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Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction

DEF header replacement parts are not available and DEF header part shortages have
necessitated the release of an ECM calibration code that allows the engine to operate normally
without engine torque and vehicle speed limits 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 allows the engine to operate normally without engine torque and vehicle speed limits
until a DEF header is available for final repair.
Along with the download of the new ECM calibration, the OEM wiring harness at the DEF header
will need to be cut at least 4 inches on the DEF header side of the wiring harness and heat shrink
repaired.
In some failure conditions the DEF header sensor can produce faults intermittently. The DEF
header sensor must be removed electrically from the OEM harness to prevent intermittent
faults as this can lead to additional warning and de-rate events.
The intent of the below procedure electrically removes the DEF header sensor from the
circuit. The DEF header must remain in the tank and connected to the DEF and coolant lines
as they are still required for vehicle operation.
Important: The steps below must be followed in order. The DEF header sensor pigtail on the DEF
header must be disconnected from OEM wiring harness prior to the download of the new ECM
calibration.
At no point is the DEF header removed from the DEF tank during this procedure.
1. Turn the keyswitch off and verify the DEF header is disconnected from the OEM harness. If the
DEF header sensor is still connected this could result in shorting of the power circuit.
2. Turn keyswitch on and start the ECM calibration download.
a. These products have new corresponding engine ECM calibrations codes that align with the
repair.
i. A Fleet Count will be required to install the new ECM calibration code.
ii. An ECM code lookup tool and complete listing of ECM codes are located at the
following link:

Note :
https://quickserve.cummins.com/qs3/qsol/service/def_header_ecm_tools.html
(https://quickserve.cummins.com/qs3/qsol/service/def_header_ecm_tools.html)
3. While the ECM calibration is downloading, use wire cutters to cut the DEF header pigtail harness
at least four inches from the connector. See Figure 1 below. Once cut, the pigtail can be moved to
a bench for ease of installation

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Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction

Figure 1, DEF Header Pigtail Harness Cut Location.
4. Remove the wire loom from the pigtail end.
5. Loop each wire and apply heat shrink tubing to each end of the wire. See Figure 2 below.

Figure 2, Heat Shrink Applied To Looped Wire.

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Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction

6. Use a heat gun to apply heat to each piece of heat shrink tubing, verify glue is extruded from the end
and sealed by pinching the end of each piece with pliers. See Figure 3 below.

Figure 3, Pliers Used to Pinch and Verify Glue Extruding.
7. After the four wires are sealed, reconnect the pigtail to the OEM wiring harness connector.
8. Secure the wiring harness using a zip tie. See Figure 4 below.

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Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction

Figure 4, OEM Wiring Harness.
1. Zip tie securing the harness
2. Pigtail connected to chassis connector
3. Harness to DEF header left unsealed
9. Verify new ECM calibration code download is completed.
Downloading this ECM calibration code and cutting of the DEF sensor header harness must be
filed in accordance with one of the appropriate TRPs. See appropriate TRP for further details.
TRP2488 – qualified engine installed in PACCAR chassis. Proper PACCAR authorization
number must be obtained, reference the TRP for further instructions.
TRP2490 – qualified engine installed in DTNA (Freightliner, Freightliner Custom Chassis,
Thomas Bus, and Western Star) chassis.
TRP2489 – qualified engines installed in Navistar® chassis
TRP2484 – qualified engines installed in the following chassis types.
Tico, Tiffin, Oshkosh Mixers, Sutphen, Gillig, ENC bus (ElDorado), Grande West
(Vicinity) Bus
Kalmar Ottawa: For Kalmar Ottawa chassis, authorization code is required prior to
repair. Kalmar dealers must enter a request in the Kalmar Case Management system
(salesforce). All non-Kalmar repair locations must contact the appropriate Kalmar
regional support area manager. The name and contact information is below:
U.S. regions:
Northeast - Christopher Pruitt 1-785-214-3401
Southeast - Warren Chase 1-785-691-5811
Midwest - Rufino Borrero 1-785-521-8002
Western - Lee Diggle 1-785-893-4474
Backup :
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Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction

Mike Conroy - 1-785-214-2988
Brian Goudreau - 1-785-214-3119
Nova Bus: For Nova Bus chassis, authorization code is required prior to repair. The
repair location must contact their local Customer Support Manager. A list of local
support managers is available in the following links (First link is for Canada. Second link
is for U.S.):

Note : https://novabus.com/parts_and_service/#customer-support-managers
(https://novabus.com/parts_and_service/#customer-support-managers)
Note : https://us.novabus.com/parts_and_service/#customer-supportmanagers (https://us.novabus.com/parts_and_service/#customer-supportmanagers)
New Flyer Industries (MCI Coach, New Flyer, and ADL)
For MCI chassis the repair location must contact their local MCI product support
representative or MCI Emergency Roadside Assistance (1-800-241-2947) to determine
if they are eligible to receive an authorization code.
For New Flyer and ADL chassis the repair location must contact their local New Flyer
product support representative to determine if they are eligible to receive an
authorization code.
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.
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Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction

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/111/111-502003.html (https://quickserve.cummins.com/qs3/pubsys2/xml/en/procedures/111/111502-003.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
Item

With Existing ECM
Calibration Code

With New ECM Calibration
Code

FC3868

Amber lamp and Malfunction
indicator lamp (MIL)/Torque and
speed inducement

No lamps/ no torque and speed
inducement

FC4572

Amber lamp and MIL/Torque
and speed inducement

No lamps/ no torque and speed
inducement

FC4677

Amber lamp and MIL/Torque
and speed inducement

No lamps/ no torque and speed
inducement

DEF Level

DEF gauge is not
accurate/Electronic service tool
is not accurate

DEF gauge is not
accurate/Electronic service tool
is not accurate

DEF Temperature

Electronic service tool is not
accurate

Electronic service tool is not
accurate

DEF Quality

Electronic service tool is not
accurate

Electronic service tool is not
accurate

Document History
Date

Details

2021-8-26

Module Created

2021-9-16

Updated Resolution section and updated Table 4 and Table 6.

2021-9-17

Added B6.7 CM2350 B121B, deleted Tables 2, 3, 4, 5, 6, 7, and 8, and
added link to PDF that includes all ECM calibration codes.

2021-9-19

Added mention of Tiffin in Resolution section.

2021-9-23

Added reference to TRP2488 and TRP2490. Added Note in issue section.

2021-9-27

Added mention of Oshkosh in Resolution section.

2021-9-28

Added mention of Stuphen in Resolution section.

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Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction

Date

Details

2021-9-30

Fixed typo.

2021-10-18

Added Gillig and exclusion of engines built in 2021 for B6.7 CM2350
B121B.

2021-10-21

Updated Product Affected with ISX15 CM2350 X101

2021-10-28

Added L9 CM2350 L123B and Nova Bus.

2021-10-29

Removed ISX15 CM2350 X101 and L9 CM2350 L123B. Added
instruction for Nova Bus.

2021-11-5

Add 2 SMNs

2021-11-5

Non-Product Problem Solving (PPS)

2021-11-8

Added ISL9 CM2350 L101.

2021-11-8

Updated Product Affected with (Engines built in 2016 only) for select
engines.

2021-11-12

Added L9 CM2350 L123B.

2021-11-15

Added ISB6.7 CM2350 B101 (Engines built in 2016 only). Added ENC
bus and ADL.

2021-11-17

Added Grande West (Vicinity) Bus

2021-12-2

Added OEMs and Kalmar contact information.

Last Modified: 02-Dec-2021

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