TSB210187

10/4/21, 10:14 AM
Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction
Technical Service Bulletin
Technical Service Bulletin: TSB210187
Released Date: 30-Sep-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
B6.7 CM2450 B155B
L9 CM2350 L116B
L9 CM2450 L126B
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:
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
https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2021/tsb210187.html
1/4
10/4/21, 10:14 AM
Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction
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.
Downloading this ECM calibration code must be filed in accordance with one of the
appropriate TRPs. See TRP2484 or TRP2489 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
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.
https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2021/tsb210187.html
2/4
10/4/21, 10:14 AM
Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction
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.
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)
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/111/111502-003.html
(https://quickserve.cummins.com/qs3/pubsys2/xml/en/procedures/111/111-502003.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
https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2021/tsb210187.html
3/4
10/4/21, 10:14 AM
Fault Codes 3868, 4572 and 4677 Caused by Diesel Exhaust Fluid (DEF) Header Malfunction
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.
2021-9-30
Fixed typo.
Last Modified: 30-Sep-2021
https://quickserve.cummins.com/qs3/pubsys2/xml/en/tsb/2021/tsb210187.html
4/4