PRODUCT SUPPORT PROGRAM FOR INSTALLING DEF INJECTOR COOLANT TANK AND LATEST ENGINE SOFTWARE ON CERTAIN 525D, 535D, 545D, AND 555D WHEEL SKIDDERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING DEF INJECTOR COOLANT TANK AND LATEST ENGINE SOFTWARE ON CERTAIN 525D, 535D, 545D, AND 555D WHEEL SKIDDERS

Usage:

TEBE5390-00

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19Dec2016

U-663

D-558

O-558

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR INSTALLING DEF INJECTOR COOLANT TANK AND LATEST ENGINE SOFTWARE ON CERTAIN 525D, 535D, 545D, AND 555D WHEEL SKIDDERS
108I 108K 1091 108T 1051		PS53368

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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 can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53368" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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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TERMINATION DATE

31Dec2018

PROBLEM

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The existing DEF Injector can fail on certain 525D, 535D, 545D, and 555D Wheel Skidders. If the existing DEF Injector fails it can cause the machine to derate.

AFFECTED PRODUCT

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Model	Identification Number
525D	GKP00100-00415
535D	MTP00100-00330
545D	KGP00100-00220
555D	PGY00100-00142

PARTS NEEDED

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Qty	Part Number	Description
2	5P4115	WASHER-HARD
2	6S8620	CLAMP-HOSE
4	8T4121	WASHER-HARD
2	8T4171	BOLT-HEX HEAD
2	8T4195	BOLT-HEX HEAD
1	3550632	CONNECTOR-SPL
1	4609257	INJECTOR AS-DEF
1	4719926	TANK AS-ALUMINUM
1	4719927	PLATE AS
2	4719928	PLATE AS
9	4721116	HOSE-BULK (9cm)
1	5218238	SFWR GP-A1000
1	BULK_COOLANT	COOLANT - See Action Required
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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1. Replace the DEF Injector, As per the Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install". Please ensure that the coolant drained from the system is stored in a suitable storage container and not refilled until the end of the following procedure.

2. Position bracket assembly 471-9927 onto the CEM. Ensure that the bracket is correctly orientated. As per Image 1

3. Position the two 471-9928 plates onto the CEM and install 8T-4195 bolts with the 8T-4121 washers. As per Image 2

4. Position coolant tank 471-9926 onto bracket. Install bolts 8T-4171 with 5P-4115 washer. Tighten to 9 Nm. As per Image 1

5. Remove coolant supply hose 349-6234 from DEF injector and connect to tank 471-9926 inlet using existing clamp. As per Image 1

6. Connect hose assembly 472-1116 (9cm) to tank 471-9926 and the DEF injector. Secure with 2 off 6S?8620 clamps, As per Image 1

7. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, ?Cooling System Coolant - Change? for the correct procedure. If required, top up the coolant system.

8. Flash the engine ECM with the software or latest available in SIS Web.
For flash programming the engine ECM, refer to Troubleshooting, "Flash Programming".

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Image1

Image2

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%
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%