DEF Sensor Emulator for Cummins

Diesel Exhaust Fluid or DEF sensor emulator is set to 75 - 95% fluid level(depends on size of the DEF tank), temperature set at ambient air temperature, and fluid quality at 32.5%. Electrical connection is a DT 4 pin deutsch plug commonly used on Shaw Development DEF sensor heads.

How to use DEF Sensor Emulator:

Locate the DEF head

• The first step is to locate the DEF head in your Power Pack. Most Power Packs have the DEF head situated at the front passenger side. Be sure to locate the DEF head since you will need to work on it. The DEF head is located at the top of the DEF tank.

Remove the cable

• You will need to remove the cable that runs from the top of the DEF head. Be sure to remove the side that has the DT4 adaptor.

Plug in the simulator

• You will need to plug in the simulator and you can zip tie it near the area. This will emulate the DEF head and should be back up and running after a couple of minutes.

• Note that plugging in the emulator is just a temporary solution. You will need to get to a professional as soon as you can. The emulator can help you if you are stranded. Once you get to an expert, you will need to replace the DEF head or get it repaired.

History of DEF sensors

DEF Sensor Issues

The DEF head are inserted into the top of the DEF tank. The head consists of the DEF pickup tube, the engine coolant heater tube and the DEF sensor. The sensor was originally designed to sense the level of DEF in the tank but in 2016 the EPA mandated that new sensor designs were required that also detected the concentration level of DEF to ensure that owners weren’t diluting their DEF with water and rendering the emissions system ineffective. These sensors showed up mainly in the 2017. Unfortunately, while the original 2016 and prior year sensors were trouble-free, these new sensors began failing at a rapid rate. These sensors were made by Shaw and had issues where the electronic circuit board had failed, which was determined to be heat related due to the close proximity of the engine’s exhaust system as well as the fact that hot engine coolant was constantly circulating through the DEF head.

When the sensor failed the engine would shut down, or goes into limp mode, typically displaying one of the following fault codes showing abnormal update rates:

            SPN 3364 FMI 9 (Cummins Fault Code 3868) –DEF quality

            SPN 1761 FMI 9 (Cummins Fault Code 4677) – DEF tank level

            SPN 3031 FMI 9 (Cummins Fault Code 4572) – DEF tank temperature

These codes were designed to detect weak DEF, low DEF level or DEF that had been overheated in the tank. If the sensor chip fails any one of these fault codes may appear, even though there is nothing wrong with the DEF itself. But the faulty sensor will derate and eventually shut down your engine.

Important information

Your dashboard DEF Gauge will no longer be accurate!!  You MUST manually monitor and continue to keep your DEF tank filled with fresh DEF fluid until you get a permanent repair.  It is highly recommended that you keep accurate records and check your DEF level at regular intervals.

Legal Disclaimer 

NOTICE:
DEF Emulator’s are not designed or intended to be used as an automotive CAT, DPF or EGR delete kit, or an aftermarket defeat device which violates the Clean Air Act.Title II. Any of our products used in this manner are void from our warranty, will not be supported and the practice is expressly discouraged. If you have any questions on emissions regulations, please check with your local state laws and regulations.

Armotech LLC., its employees, dealers and/or business associates will not be held liable for any reason and the customer assumes all responsibility for the proper use of our products. 

It is illegal to modify or tamper with a vehicle’s emissions system in an effort to defeat the DEF system.