AdBlue problem on Bergmann: Solving Emission Control System Problems with Engine Computer Flash

Introduction

When an emission management system reports faults on an industrial vehicle, such as an AdBlue problem on Bergmann, it’s crucial to act quickly to maintain engine performance and minimize emissions. Recently, we identified several error codes on our Bergmann Dumper equipped with a Cummins QSB4.5 engine and a CM2350 ECU. In this article, we will explore these faults, discuss their possible meanings and explain how we resolved them by reprogramming the engine ECU to correct the problem.

Bergmann AdBlue Fault Codes

The faults we encountered were varied, mainly related to the emission control system and the AdBlue problem on Bergmann. Here’s the full list of error codes we identified:

Error code 3868: Aftertreatment 1 Diesel Exhaust Fluid Quality – Abnormal Update Rate
This code reported a high frequency of incorrect SCR fluid quality updates, linked to the AdBlue problem. This may be due to faulty sensors or communication problems.

Error code 4677: Aftertreatment 1 Diesel Exhaust Fluid Tank Level – Abnormal Update Rate
This fault indicated incorrect SCR fluid level updates. It could be caused by faulty sensors or communication problems.

Error code 4572: Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature – Abnormal Update Rate
This code concerned incorrect updates of the SCR fluid temperature. Faulty sensors or communication problems could be at the root of this fault.

Error Code 3714: Engine Protection Torque Derate – Condition Exists
This code limited engine torque due to abnormal conditions, affecting the AdBlue problem on Bergmann. Several factors, including problems in the emission control system, cause the engine to fail, preventing the dumper from being used.

Error code 3712: Aftertreatment SCR Operator Inducement – Data Valid But Above Normal Operation
This fault suggested operator inducement for the SCR system, but the data indicated abnormal operation above normal, in connection with the above problem.

Error Code 3232: Aftertreatment 1 Intake NOx Sensor – Abnormal Update Rate
This code reported incorrect updates of the SCR intake NOx sensor frequency. Sensor or communication problems were possible.

Error code 2771: Aftertreatment 1 Outlet NOx Sensor – Abnormal Update Rate
This fault was similar to the previous one, but concerned the output NOx sensor of the SCR system.

Error Code 3559: Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit – Voltage Below Normal or Shorted to High
This code suggested an abnormally low voltage or short circuit in the SCR fluid dosing unit.

Possible causes

The fault codes we have identified can have various origins. In particular, communication problems are frequently observed. The emission control system requires precise communication between the various components. Interruptions or errors in communication between the engine ECU, sensors and actuators can result in fault codes.

Final Solutions: Tailor-made program development

Let’s take a look at the solutions we’ve put in place to solve these problems. Focusing on the engine ECU flash for definitive fault clearance to eliminate the AdBlue problem on Bergmann.

Engine ECU Flash

The final solution to permanently eliminate the error codes was to flash the engine ECU. This operation reset the ECU, erased the error codes and updated the software to optimize the operation of the emission control system.

We performed the engine ECU flash, and the software updates are specifically designed to solve the problems we had identified. After this operation, the anti-pollution system underwent rigorous testing to ensure that it was working properly, thus putting an end to the AdBlue problem on Bergmann.

Conclusion

In short, solving emission system problems requires a methodical approach. First of all, you identify the fault codes, then overhaul the faulty components, check the communication, manage the power supply and check the quality of the AdBlue fluid. If, after checking, the faults are still present, you need to go further. Engine ECU flash represents the ultimate solution for permanently eliminating faults and optimizing emission control system performance.

So, by taking these steps, our Bergmann Dumper has regained its reliability and performance, and above all, permanently. As you can see from this photo, after our intervention there were no more defects, either passive or active.

Find out more about our interventions

On Cummins engine but also on Bergmann.