PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW SOFTWARE AND POSSIBLY REPLACING THE INJECTOR NOZZLE ON CERTAIN RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW SOFTWARE AND POSSIBLY REPLACING THE INJECTOR NOZZLE ON CERTAIN RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS

Usage:

TEBE7068-01

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21Dec2017

(Revised 31May2018)

U-734

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Before/After	PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW SOFTWARE AND POSSIBLY REPLACING THE INJECTOR NOZZLE ON CERTAIN RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS
1920 108D 7620		PS45741

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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 "PS45741" 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 21Dec2017 Service Letter. Changes have been made to the Problem, Affected Product, Parts Needed, Action Required, and Service Claim Allowances.

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TERMINATION DATE

31Dec2018

PROBLEM

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Certain Retrofit Selective Catalytic Reduction Systems equipped with a 485-2864 dosing cabinet logs a DEF pressure code causing the DEF system to shut down.

4331-11 Commissioning code will go active if the ASFT and Commissioning tests are not successfully completed prior to flashing the new software.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
AFTERTREAT-SCR	EH700001-00003 EH800001-00068 EH900001-00157

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*****Group 2*****
AFTERTREAT-SCR	EH600047-00053

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3332400	GASKET
1	3520865	NOZZLE GP-DEF
1	5496259	SFWR GP-A1015
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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.
*****Group 2*****
1	5494181	SFWR GP-A1015
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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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Group 1: Replace the injector nozzle group and replace the software in the dosing cabinet with software part number 549-6259 or latest available on SIS Web. Refer to the attached Rework Procedure for instructions on replacing the nozzle.

Group 2: Replace the software in the dosing cabinet with part number 549-4181 or latest available on SIS Web. The software update is all that is required for Affected Product in Group 2.

For Both Groups 1 and 2:

ON AN ALREADY COMISSIONED SYSTEM:
Complete the AFST prior to flashing the new AT software

ON A NEW SYSTEM:
Flash the new software.
Complete the Commissioning and the ASFT.

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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%
*****Group 1*****
0-8000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.0-hour job for Group 1
Reasonable travel time and mileage will be allowed. Up to $350 will be allowed for man lift rental to access the injector group.

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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%
*****Group 2*****
0-500 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

For Group 1 Only:

Step 1: Ensure CEM has cooled prior to beginning work. Use a temp gun to ensure that the temperature of the injector is at a safe to handle temperature.

Image1.1.1

Step 2: Once the CEM is at a safe temperature to begin work, remove air and DEF line connections at the injector. Ensure all permits and appropriate scaffolding or man-lift type equipment with sufficient personnel are on site or available if needed. This procedure may require two individuals with all the required PPE to handle the weight and distance to reach for work to be performed.

Image1.2.1

Step 3: Remove eight bolts and remove injector assembly from the CEM. This step may require two individuals due to the weight of the injector.

Step 4: Remove the nozzle group from the injector.

Image1.4.1

Step 5: Apply Loctite (nickel free) dry film anti-seize on the threads of the 352-0865 nozzle group. Ensure that only the threads receive anti-seize as the nozzle could suffer plugging if anti-seize contaminates the tip. Install the nozzle group with a new gasket onto the injector group and tighten to 9 +/- 2 Nm.

Image1.5.1

Step 6: Reinstall the injector with new nozzle and new gasket into the CEM matching alignment notches and tighten the eight (8) mounting bolts to standard torque. This step may require two individuals due to the weight of the injector.

Image1.6.1

Step 7: Using a stamping die set, the old injector part number must be removed. This can be accomplished using the X stamp and stamping out all of the part numbers (XXXXXXXX) or a grinder can be used to permanently remove the part number.

Step 8: Using the stamping die set, stamp part number 549-2925 on the flange of the injector as shown in image 1.6.1.

Step 9: Install software part number 549-6259 into the dosing cabinet ECM.

Please note that re-commissioning of the SCR system is not required after the software update if the system has already been commissioned.