We have a truck at work with the "Engine Idled, See Manual" warning on the dash. The truck wont go over 5 MPH. There are no codes. All the EGT sensors are reading correctly. DEF tank is full and reads full. Reductant injector sprays DEF, maintains 72 psi reductant pump line pressure. We have tried all the "drive cycle" tests but can not get the warning to clear.

The only thing that seems off to me is the Exhaust Gas Recirculation Temp sensor Bank 1 Location 1 always reads -40 F. Always. We have another truck that is running just fine and it also reads -40 F.

This is a truck used in an underground mine and heavily regulated for DPM's so while we would love to delete it, thats just not an option.

Any ideas?

 

Do you have access to IDS? If so, possibly try this attached TSB 14-0192. Unless this is one of the drive cycle tests you tried.

 

I have been trying that drive cycle. I get the EGT up to 190 and the reductant line pressure comes up but then the duty cycle never starts its square wave. Duty cycle just reads 0. When i am driving the truck though the duty cycle is coming on and off (5-10%), just not while doing the drive cycle. I had never reprogrammed the PCM like in the write up you provided. I did just check though and is says "No later calibration is available on the system for this PCM". So i'm assuming its all up to date.

The drive cycles only work AFTER a problem is fixed, correct? Could there be something wrong in the emission system but not throw any codes or warnings that i may be missing? All the EGT and NoX sensors seem to be reading fine.

 

So after trying this drive cycle about 50 times over the 4 different crews here at work it finally cleared last night. We didnt change any sensors or do anything other than the (multiple) drive cycles. I cant imagine how frustrating this would be for a mechanic who is making flat rate! Thanks for the help.

 

I think it's fairly easy, just have to follow the guided steps. For anyone with Ford's IDS, I would assume there is a manual included (for the cost of it). There is a reprogramming menu for PCM and TCM. My guess it's already been updated at some point being a 2014. My 2011 has a lot of versions, I wish I would have snapped a picture of the screen when a technician was showing me. This was in late June and there was even a June 2018 release for the 2011.

My understanding also of drive cycles is the "problem" must be resolved before a successful cycle will complete for that process. However, I am not a vehicle technician so I'm only going off of what I remember hearing.

Have you ruled out a bad ground or any wires that may be rubbing on something? Maybe it's sporadic after bouncing down a dirt road and at the next KOEO, the PCM briefly cannot communicate to an SCR component causing this error. I read this as you've been thorough since this is what you do but I'm just throwing out random ideas to troubleshoot. After having to repeat the procedure so many times, I would be surprised if the issue doesn't return.

 

I work on underground heavy equipment. I am NOT a light vehicle mechanic... not even close. This is the first time i have ever messed around with IDS or any DEF system for that matter. I could have easily overlooked something but we did not fix anything on the truck. I guess only time will tell if its fixed. Something tells me it will come back at some point.

 

This doesnt really have anything much to do with your problem.

How is pollution monitored in the mines? Obviously you want as less as possible due to O2 level concerns. Willing to share? I'd love to hear!

 

They have gas meters that tell you when DPMs or CO (and a bunch of other gasses) are too high. We have to do DPM tests on all the equipment when it comes in for PM. If DPMs get to high in a certain area of the mine they just shut down that level and go to another for an hour or so to let the ventilation flush it out. None of our equipment has and DPF or SCR system... yet. Im sure its coming in the near future.