DEF Injector Troubleshooting on Certain C4.4 Engines {108I} Caterpillar

DEF Injector Troubleshooting on Certain C4.4 Engines {108I}

Usage:

Asphalt Compactor: CB64B (S/N: C561-UP); CB66B (S/N: B661-UP); CB68B (S/N: C681-UP); CCS9 (S/N: C521-UP)
Asphalt Paver: AP500F (S/N: 4491-UP); AP555F (S/N: AP51-UP); AP600F (S/N: AP61-UP); 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-UP); 430F2 ST (S/N: HWE1-UP); 432F2 (S/N: HWP1-UP); 434F2 (S/N: HWR1-UP); 444F2 (S/N: HWS1-UP)
Compact Wheel Loader: 910M (S/N: H221-UP); 914M (S/N: H241-UP); 918M (S/N: H261-UP)
Engine: C4.4 (S/N: JKT1-UP)
Excavator: 312F (S/N: KMK1-UP); 313F (S/N: DJE1-UP; PRG1-UP); 314F (S/N: LFC1-UP); 315F (S/N: TDY1-UP); 316F (S/N: YDL1-UP; ECZ1-UP); 318F (S/N: HCP1-UP; FFT1-UP); 320F (S/N: NHD1-UP; YBM1-UP); 323F (S/N: YEC1-UP); 325F (S/N: XAA1-UP; YCA1-UP)
Mobile Hydraulic Power Unit: 316F-MHPU (S/N: HS31-UP)
Pipelayer: PL61 (S/N: S3H1-UP)
Pneumatic Compactor: CW34 (S/N: AL31-174,176-UP)
Telehandler: TL1055D (S/N: ML51-UP); TL1255D (S/N: ML71-UP)
Track-Type Tractor: D3K2 (S/N: KF21-UP; KL21-UP; JPJ1-UP); D4K2 (S/N: KM21-UP; KR21-UP); D5K2 (S/N: KW21-UP; KY21-UP; RRE1-UP); D6K2 (S/N: DFR1-UP; JTR1-UP)
Vibratory Soil Compactor: CP54B (S/N: P541-UP); CP56B (S/N: 485103-UP); CP68B (S/N: P681-UP); CP74B (S/N: P741-UP); CS54B (S/N: 482145-UP; CS51-UP); CS56B (S/N: 484139-UP; S561-UP); CS64B (S/N: CW61-UP; 486144-UP); CS66B (S/N: S661-UP; 487199-UP); CS68B (S/N: CS81-UP; 488119-UP); CS74B (S/N: 490124-UP; CS41-UP); CS76B (S/N: 4921-UP); CS78B (S/N: 493124-UP; S781-UP)
Wheeled Excavator: M314F (S/N: F4A1-UP); M316F (S/N: F6N1-UP)

Introduction

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

Problem

There have been some instances of faults with the 459-7216 DEF Injector & Mounting Gp. The faults can lead to the Diesel Exhaust Fluid (DEF) injector not dosing correctly. Diagnostic trouble codes and operator inducements may become active due to these faults.

Solution

Follow the correct troubleshooting procedure for any diagnostic codes related to the DEF system. Refer to Troubleshooting for the correct procedure. Diagnostic code 3361–5 Aftertreatment #1 DEF Dosing Unit : Current Below Normal has been reported, which may lead to operator inducement diagnostic codes 5246-15 Aftertreatment SCR Operator Inducement : Severity : High - least severe (1) and 5246-16 Aftertreatment SCR Operator Inducement : Severity : High - moderate severity.

If the troubleshooting procedure indicates a DEF injector fault, perform the following procedure:

Ensure that the latest engine software is installed on the engine ECM. Refer to Troubleshooting, ECM Software - Install for the correct procedure.
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Illustration 1 g06123677

View of the 459-7216 DEF Injector & Mounting Gp
(1) DEF injector part number
(2) Cavity number
Record the DEF injector part number (1), serial number, and cavity number (2).
Note: The cavity number will be either a "1", a "2", or a "3".
If the DEF injector serial number is between "SN150702094314" and "SN160722000000" and the cavity number is "1", continue with this procedure.
If the DEF injector serial number is outside of the range specified above, proceed to Test Step 4.
If the cavity number is "2" or a "3", proceed to Test Step 4.
1. Install a replacement DEF injector. Refer to Disassembly and Assembly, DEF Injector and Mounting - Remove and Install.
  If the replacement DEF injector serial number is between "SN150702094314" and "SN160722000000" and the cavity number is "1", do not install the injector.
2. Store the injector for 60 days and log the service claim. The removed injector will be requested for return through the Send It Back (SIB) process. Reference the reason for rejection and Media Number M0076368 in the service claim.
3. Take a Product Status Report (PSR) from the affected engine.
4. Perform the following steps to take an "Abnormal Shutdown Report" (ASR) from the engine:
  1. From the "File" menu, select "Select ECM".
  2. Select the "C4.4" ECM.
  3. From the "Information" menu, go to "History", then select "Aftertreatment Abnormal Shutdown History".
  4. Select "Save to File".
5. Submit the PSR and ASR using "CPI Feedback" within Service Information Systems (SIMSi). Include TIB Media Number M0076368 and CPI number 375452. Include the following information on the report:
  - Machine location (city, state, country)
  - Machine manufacturer and sales model
  - Regeneration summary report from the engine ECM
  - Warranty report from the ECM
  - Engine operating hours
  - Description of the fault, troubleshooting steps taken, and details of parts replaced
  - Serial number of the DEF injector that was replaced, including a photograph of DEF injector showing the serial number tag
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Illustration 2 g06123720

Typical example of a contaminated DEF injector connector
Inspect the DEF injector for evidence of leaks. Inspect the electrical connector for contamination. Refer to Illustration 2.
If evidence of leaks or DEF contamination is identified, install a replacement DEF injector. Refer to Disassembly and Assembly, DEF Injector and Mounting - Remove and Install.
If no evidence of leaks or DEF contamination is identified, reinstall the DEF injector. Ensure that a new 446-1271 Gasket and 446-1273 Clamp As are used when installing the DEF injector. Refer to Disassembly and Assembly, DEF Injector and Mounting - Remove and Install.
1. If the injector is replaced, store the removed injector for 60 days and log the service claim. The removed injector will be requested for return through the Send It Back (SIB) process. Include a paper copy of the Product Status Report (PSR) with the returned injector.
2. Take a Product Status Report (PSR) from the affected engine.
3. Perform the following steps to take an "Abnormal Shutdown Report" (ASR) from the engine:
  1. From the "File" menu, select "Select ECM".
  2. Select the "C4.4" ECM.
  3. From the "Information" menu, go to "History", then select "Aftertreatment Abnormal Shutdown History".
  4. Select "Save to File".
4. Submit the PSR and ASR using "CPI Feedback" within Service Information Systems (SIMSi). Include TIB Media Number , M0076368 and CPI number 375452. Include the following information on the report:
  - Machine location (city, state, country)
  - Machine manufacturer and sales model
  - Regeneration summary report from the engine ECM
  - Warranty report from the ECM
  - Engine operating hours
  - Description of the fault, troubleshooting steps taken, and details of parts replaced
  - Serial number of the DEF injector that was replaced, including a photograph of DEF injector showing the serial number tag
Check the wiring harness for DEF contamination. If necessary, repair the wiring harness using 437-1451 Wire Connection Kit.
Photograph the wiring harness connector and include the photograph on the SIMSi report.