Diesel Exhaust Fluid (DEF) Manifold on Certain C3.4B and C4.4 Engines {108K, 3206} Caterpillar

Diesel Exhaust Fluid (DEF) Manifold on Certain C3.4B and C4.4 Engines {108K, 3206}

Usage:

Asphalt Compactor: CB66B (S/N: B661-UP)
Asphalt Paver: AP655F (S/N: MH61-UP)
Backhoe Loader: 416F2 (S/N: HWB1-UP); 420F2 IT (S/N: HWD1-UP); 420F2 ST (S/N: HWC1-UP); 428F2 (S/N: HWN1-UP); 430F2 IT (S/N: HWG1-234,236-UP); 430F2 ST (S/N: HWE1-325,327-UP); 432F2 (S/N: HWP1-1317,1319-UP); 434F2 (S/N: HWR1-UP); 444F2 (S/N: HWS1-298,301-UP)
Compact Wheel Loader: 914M (S/N: H241-421,423-UP); 918M (S/N: H261-UP)
Engine: C3.4B (S/N: CJ71-654,656-657,659-UP); C4.4 (S/N: JKT1-7,9-9,11-11,13-18,20-546,548-667,669-1226,1230-1444,1447-1515,1517-2177,2180-2196,2200-2200,2202-2266,2268-2287,2289-2298,2304-2346,2352-2352,2360-2453,2455-2472,2474-2532,2534-2610,2612-2782,2784-3088,3094-3103,3109-3178,3180-3200,3206-3235,3241-3271,3289-3317,3321-3327,3330-3330,3332-3334,3339-3378,3383-3562,3568-3585,3603-3617,3623-3629,3640-3681,3692-3722,3733-3736,3756-3761,3763-3877,3898-3936,3947-3979,3985-4060,4071-4080,4091-4164,4167-4171,4173-4198,4209-4224,4226-4274,4285-4304,4306-4648,4650-4688,4699-4727,4735-4745,4753-4754,4756-4769,4774-4783,4785-4785,4787-4795,4801-4802,4824-4825,4828-4828,4868-UP)
Engine Package: 3.4B (S/N: CJ71-654,656-657,659-UP)
Excavator: 313F (S/N: DH81-103,10001-UP; DJE1-244,10180-UP; NLG1-UP; PRG1-241,10001-UP); 315F (S/N: TDY1-426,10001-UP); 316F (S/N: YDL1-1,134-363,10001-UP; ECZ1-188,10049-UP); 318F (S/N: HCP1-152,10001-UP; FFT1-206,10022-UP); 320F (S/N: NHD1-280,10469-UP; YBM1-1,159-416,10001-UP); 323F (S/N: YEC1-188,10001-10089,10091-UP); 323F SA (S/N: FA21-UP); 325F (S/N: XAA1-181,183-474,10001-UP; YCA1-384,10001-UP)
Mobile Hydraulic Power Unit: 316F-MHPU (S/N: HS31-1,10101-10101,90102-90103,90200-UP)
OEM Mobile Hydraulic Power Unit: 323F SA MHPU (S/N: P7P1-UP)
Pneumatic Compactor: CW16 (S/N: TL51-UP)
Telehandler: TL1055D (S/N: ML51-764,767-1115,1120-1120,1122-1130,1508-UP); TL1255D (S/N: ML71-156,158-1038,1046-1049,1054-UP); TL642D (S/N: ML81-782,832-UP); TL943D (S/N: MLJ1-1,153-560,1153-UP)
Track-Type Tractor: D3K2 (S/N: KF21-1,113-114,150-263,2110-UP); D4K2 (S/N: KR21-1,142-142,175-346,2140-UP); D5K2 (S/N: KW21-151,154-155,200-672,2150-2241,2243-2800,2802-2825,2827-UP; KY21-162,164-164,225-933,2160-3103,3105-3383,3385-UP); D6K2 (S/N: DFR1-522,524-525,527-UP; JTR1-1,200-939,941-954,956-UP)
Vibratory Soil Compactor: CP44B (S/N: 4P41-UP); CS54B (S/N: 482180-UP; CS51-UP); CS56B (S/N: 484183-UP; S561-UP); CS66B (S/N: S661-UP; 487328-UP); CS74B (S/N: 4901-UP)
Wheeled Excavator: M314F (S/N: FB41-UP; F4A663-UP); M316F (S/N: FB61-UP; F6N303-UP)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

There have been issues with the following DEF manifolds:

462-3219 DEF Manifold Gp
462-3232 DEF Manifold Gp
462-3610 DEF Manifold Gp

The issues result in erratic or inaccurate DEF levels being recorded. This condition causes diagnostic codes and operator inducement strategies to be triggered.

Solution

Caterpillar is aware of the problem, but an interim repair has not been defined.

Make a note of the operating conditions of the engine when the errors are occurring (for example, at key on or during normal operation).

Operate the engine at low idle without moving the machine for 30 seconds. Make a note of whether the DEF level reading returns to normal.

Check the integrity of the wiring harness on top of the DEF manifold.

Use the electronic service tool to take a Product Status Report (PSR) with the histogram feature selected.

Install a replacement DEF manifold. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install for the correct procedure.

When the DEF manifold has been removed, turn the DEF manifold upside down in a quiet environment to understand whether the level float is sticking. The sound of the float hitting the top of the tube should be heard if the float is not stuck.

Take photographs of the removed DEF manifold. Focus the photographs around the bottom of the DEF tank header unit

Retain the removed DEF manifold for 30 days. The DEF manifold will be requested for return using the Send It Back (SIB) process.

Note: Ensure that the DEF manifold is packaged so that the bottom is protected from damage and contamination.

Submit the following information through "CPI Feedback" within the Service Information Management System: