PRODUCT SUPPORT PROGRAM FOR REWORKING THE 458-8220 DEF CONTROL GROUP ON CERTAIN RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE 458-8220 DEF CONTROL GROUP ON CERTAIN RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS

Usage:

TEBE6825-01

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16Nov2017

(Revised 07Feb2018)

U-633

A-450

D-535

O-527

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING THE 458-8220 DEF CONTROL GROUP ON CERTAIN RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS
108K 108H		PS45691

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS45691" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 16Nov2017 Service Letter. Changes have been made to the Service Claim Allowances.

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TERMINATION DATE

31Oct2018

PROBLEM

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The existing DEF control group can fail and lock up on certain Retrofit Selective Catalytic Reduction Systems. If the existing control group fails it can keep the DEF dosing pump running even with the engine inactive and can potentially flood the engine.

AFFECTED PRODUCT

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Model	Identification Number
AFTERTREAT-SCR	ES700101-00333, 335-365, 11143 ESH00001, 109-131

PARTS NEEDED

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Qty	Part Number	Description
2	1093038	WIRE-END
4	1108714	END-WIRE
305	2361222	WIRE-BULK (305 CM)
305	2361223	WIRE-BULK (305 CM)
1	3368570	DIODE
1	3368571	RETAINING CLAMP
1	3715027	BASE-RELAY
1	3715029	RELAY
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Add a 24V relay that is activated from the EMCP panel "Engine Started" output to control power to the (DEF) dosing pump. Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-50000 hrs, 0-132 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 4.0-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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Conduit as required ? site specific requirements

- (120mm) 8C8796 Bulk OR EQUIVALENT -16 gauge jumper wire (white) ? relay to power junction- with (2) 109-3038 ferrule ends.

- (length as needed) 236-1222 Bulk OR EQUIVALENT -18 gauge red, 24v power wire from EMCP panel to (+) relay.
- Ferrule (2) 110-8714 - each end of wire

- (length as needed) 236-1223 OR EQUIVALENT -Bulk 18 gauge black, 24v ground wire from EMCP panel to (-) relay.
- Ferrule (2) 110-8714 - each end of wire

Open dosing cabinet door.
Reference area for first step.
Junction panel at top right corner of the gray dosing cabinet.

Image1.2.1

Image1.2.2

Current AC voltage to junction box and to dosing pump.

Image1.3.1

Change to dosing pump wiring:

Image1.4.1

Image1.4.2

Image1.4.3

Step 1:

Disconnect the 110V power supply to the cabinet. With an AC volt meter, verify that there is no power to the junction box. Check for voltage between the black wires/blue section of the box and the white wires/grey section of the box.

Image1.5.1

Step 2:

Suggested cabinet access.
(Optional) Depending on installations. Some installations already have knockouts for conduit installed and those can be used if conduit is not full or already installed.
Open the cabinet and verify that there is no risk of damaging current wiring or components.
Drill hole in the cabinet in the area shown below. This hole size is determined by conduit used.

Image1.6.1

Step 3:

Arrange components as shown in the new stack up starting with the relay and adjust accordingly to the left.

Image1.7.1

Image1.7.2

Step 5:

-(120 mm) 8C8796 Bulk or equivalent -16 gauge jumper wire (white) ? relay to power junction - with (2) 109-3038 ferrule ends.
Build a jumper wire using the components above. Install one end in the socket that the pump wire was removed from on the previous step.

Image1.8.1

Step 6:

Route (2) 18AWG wires from EMCP panel to relay.

Terminals: Digital Output 2 (DOut 2) and Battery 24VDC + on terminal strip in EMCP panel
Route both wires through existing conduit per site requirements.
Terminate wires as outlined below.
Note that length of wires will be determined by the distance to the Dosing Cabinet
EMCP Terminal Strip: Battery 24VDC+ in EMCP panel to A1 on relay.
236-1222 Bulk or equivalent 18 awg red wire.

EMCP Terminal Strip: Digital Output 2 (DOut 2) in EMCP panel to A2 on relay.
236-1223 Bulk or equivalent 18 awg black wire.

Note - Use Ferrules 110-8714 - at each end of all wires.

Image1.9.1

Step 7 Program EMCP for Run Relay

Digital Output Programming:

Select your EMCP from the list of ECM?s

Image1.10.1

Select ?Configuration? from Service drop down menu

Image1.11.1

Select ?Digital Outputs? from the EMCP you chose.

Image1.12.1

Double click ?Digital Output #2 Usage Type? and select ?Command/Status Parameter
from the ?New Value? drop down menu. Click ?OK?

Image1.13.1

Select ?Digital Output #2 Command/Status Parameter Data Identifications and
Select ?Air Shutoff? from ?New Value? drop down menu.

Image1.14.1

Open Drop down menu and select ?Engine Started.? Click ?OK?
Programming for digital output complete. Refer to UENR1209, page 218 for
information on wiring the relay.

Image1.15.1

Step 8: Verify the operation of install.

Reconnect the 110V power supply to the cabinet. Verify that the unit is powered.
Fan running, inverter and Ethernet Switch lights on, etc. With engine not running
Verify that the DEF pump Neutral at Relay is open to Ground.

Start engine.

Verify that the dosing pump is powered by the display being on. If dosing pump is on shut engine down and return to normal conditions.