Diesel Exhaust Fluid (DEF) Injector Are Failing on Certain C9.3-C18 Machine and Commercial Engines {108I} Caterpillar

Articulated Truck

725C (S/N: TFB1-UP)

725C2 (S/N: 2T31-UP)

730C (S/N: T281-UP; TFF1-UP)

730C2 (S/N: 2T41-UP)

730C2 EJ (S/N: 2T51-UP)

735C (S/N: TFJ1-UP)

745C (S/N: JE81-UP; TFK1-UP)

Cold Planer

PM620 (S/N: JB91-UP)

Ejector Truck

730C EJECTOR (S/N: TFH1-UP)

740C EJECTOR (S/N: TFN1-UP)

Excavator

336F (S/N: B391-UP; TZA1-UP; RKB1-UP; RBC1-UP; KGH1-UP; YBH1-UP; ZBJ1-UP; LCL1-UP; SSN1-UP; LTP1-UP; NBS1-UP; KFT1-UP; MTW1-UP; DFY1-UP; WTZ1-UP)

340F (S/N: YBF1-UP; EAR1-UP; WBX1-UP)

349F (S/N: BZ21-UP; KEA1-UP; HLB1-UP; HPD1-UP; SFG1-UP; RAX1-UP)

352F (S/N: SD21-UP; YEG1-UP; A9J1-UP; XAL1-UP; KBP1-UP)

374F (S/N: DNM1-UP)

390F (S/N: TYE1-UP; MGF1-UP; HSM1-UP)

Generator Set

C18 GEN SET (S/N: X5F1-UP)

XQ375 (S/N: X3F1-UP)

Industrial Engine

C13 (S/N: N3F1-UP)

C13 IND (S/N: JR91-UP)

C15 (S/N: N5F1-UP)

C18 (S/N: N8F1-UP)

C9.3 (S/N: CS91-UP)

Landfill Compactor

826K (S/N: 2321-UP)

836K (S/N: TWZ1-UP)

Material Handler

MH3295 (S/N: PA91-UP)

Mobile Hydraulic Power Unit

336FMHPU (S/N: B351-UP)

374F MHPU (S/N: DP41-UP)

390F MHPU (S/N: PT71-UP)

Motor Grader

12M Series 3 (S/N: N9B1-UP; N9F1-UP; N9P1-UP; N9R1-UP)

140M Series 3 (S/N: N9D1-UP; N9G1-UP; N9J1-UP; N9M1-UP)

14M Series 3 (S/N: N9S1-UP)

160M Series 3 (S/N: N9E1-UP; N9K1-UP; N9L1-UP; N9T1-UP)

16M Series 3 (S/N: N9Y1-UP)

OEM Mobile Hydraulic Power Unit

336FMHPU (S/N: B341-UP)

390F MHPU (S/N: B371-UP)

Off Highway Truck

770G (S/N: RMA1-UP; KDH1-UP)

772G (S/N: KEX1-UP)

Pipelayer

PL72 (S/N: P721-UP)

PL83 (S/N: CB21-UP)

PL87 (S/N: TEC1-UP)

Reclaimer Mixer

RM500B (S/N: MB91-UP)

Soil Compactor

825K (S/N: 2331-UP)

Track-Type Tractor

D6T (S/N: CR31-UP; CG81-UP; SGA1-UP; RAD1-UP; STE1-UP; MEL1-UP; WRN1-UP; KMR1-UP; WES1-UP; SGT1-UP; TMY1-UP; HTZ1-UP)

D6T2 (S/N: MH71-UP; JML1-UP; NDY1-UP)

D7E (S/N: HKA1-UP; SSH1-UP)

D8T (S/N: FMC1-UP; JET1-UP)

D9T (S/N: REX1-UP)

Wheel Dozer

824K (S/N: 2341-UP)

834K (S/N: TWY1-UP)

Wheel Loader

966M (S/N: DYC1-UP; LMM1-UP; KJP1-UP)

966M Series XE (S/N: P6C1-UP)

972M (S/N: GGN1-UP; A8P1-UP; JPR1-UP)

972M Series XE (S/N: EDW1-UP)

980M (S/N: KRS1-UP; N8T1-UP)

982M (S/N: F9A1-UP; K1Y1-UP)

988K (S/N: TWX1-UP)

Wheel Tractor Scraper

621K (S/N: WTA1-UP; WTE1-UP)

623K (S/N: WTB1-UP)

627K (S/N: WTC1-UP)

637K (S/N: WTS1-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

DEF injector failures are occurring at early hours on I6 engine products leading to fault codes and inducements which causes customer downtime. Failed part returns indicate that a portion of the injectors is no fault found when tested at Caterpillar^®. Caterpillar^® is investigating the root cause of these injector replacements and to support the investigation is requesting that the following procedure is completed, documented, and sent to Caterpillar^®.

Solution

Complete the steps listed below and ensure that all DEF Quality, Injector Resistance and Dosing Accuracy Test are completed when requested by the associated troubleshooting guides. Once troubleshooting is completed, submit all information to the following email address: Blunier_Derek_W@cat.com

1. Download Product Status Report including all ECMs and histograms.

2. Download Warranty Report from the engine ECM and aftertreatment ECM.
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   Illustration 1	g06067373
   DEF Injector

3. Take a picture of the DEF injector part number and serial number as shown in Illustration 1.
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   Table 1

   Media References
   Engine	Description	Media Number
   C9.3	Troubleshooting	UENR0978
   	Testing and Adjusting	UENR3402
   	Disassembly / Assembly	UENR0130
   C13	Troubleshooting	UENR0955
   	Testing and Adjusting	UENR4302
   	Disassembly / Assembly	UENR0131
   C15 / C18	Troubleshooting	UENR0955
   	Testing and Adjusting	UENR3351
   	Disassembly / Assembly	UENR0132

4. Follow the correct troubleshooting procedure from Table 1 for each corresponding code. For troubleshooting C9.3 use , UENR0978 and for C13, C15, C18 engines use , UENR0955.
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   Table 2

   DEF Quality Results
   Step	Instruction	Completed (Yes/No)	Result Comments	Units
   1	Follow the Testing and Adjusting procedure for "Diesel Exhaust Fluid Quality - Test"
   2	DEF Contamination Test (include photo of test strip if possible)			Pass/Fail
   3	DEF Concentration Test			% @ 20C

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   Table 3

   Injector Resistance Measurement
   Step	Instruction	Completed (Yes/No)	Results Comments	Units
   1	Turn the keyswitch to the OFF position. Allow 2 minutes to elapse before proceeding.
   2	Disconnect the DEF injector from the applicable harness.
   3	Inspect the connector for damage or debris (if damaged take photo)
   4	Measure the temperature of the injector (aluminum body)			C
   5	Connect two 398-4987 connectors to the DEF injector. The connectors must be used to prevent damage to the DEF injector connector.
   6	Measure the resistance of the DEF injector.			Ohms

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   Table 4

   Dosing Accuracy Test
   Step	Instruction	Completed (Yes/No)	Results Comments	Units
   1	Follow the Testing and Adjusting, Aftertreatment SCR System Dosing - Test.
   2	Remove the injector from the DPF outlet.
   3	Take a photograph of the DEF injector mount on the DPF outlet and the tip of the DEF injector.
   4	Install the injector on the beaker.
   5	Run the DEF System Dosing Accuracy test through Cat ET.
   6	Use the breaker to measure the amount of fluid from the dosing test.			ml
   7	Repeat the test to verify consistency.			ml
   8	Install the injector back onto the DPF outlet.

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   Illustration 2	g06068068
   DEF Injector Resistance Measurement

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   Illustration 3	g06067706
   Injector Mount on DPF (Outlet Sample Picture)

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   Illustration 4	g06067753
   DEF Injector Tip (Sample Picture)

5. When troubleshooting requests the DEF quality check, DEF injector resistance measurement or Dosing Accuracy Test, please document results in the Tables shown above.

6. After completing troubleshooting and performing the Aftertreatment System Functional Test, download a new Product Status Report with all ECM's.
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   Table 5

   Injector Failure Report
   Step	Instruction	Completed (Yes/No)	Results Comments	Units
   1	Download "Product Status Report" (PSR) from the engine ECM and send to the email address in the instructions.
   2	Download "Warranty Report" (WR) from the engine ECM and send to the email address in the instructions.
   3	Take a picture of the injector part number / serial number.
   4	Follow the correct TSG based on Table 1 and complete tables 2 through 4 when they apply.
   5	Perform an "Aftertreatment System Functional Test".
   6	Download "Product Status Report" (PSR) from the engine ECM and send to the email address in the instructions.
   7	Submit "TIB Check List", "Product Status Reports", DEF injector deposits photographs, CEM deposit photographs, and DEF injector part number and serial number photograph to the email address in the instructions.

7. Fill out the Injector Failure Report and send all information including product status reports, warranty reports, DEF injector and mount photos, DEF injector part number and serial number and test results to the email address provided above.