PRODUCT SUPPORT PROGRAM FOR REPLACING THE INTERNAL SUPPORT DISC WITHIN THE DIESEL EXHAUST FLUID BACK PRESSURE VALVE ON CERTAIN RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE INTERNAL SUPPORT DISC WITHIN THE DIESEL EXHAUST FLUID BACK PRESSURE VALVE ON CERTAIN RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS

Usage:

TEBE0326-00

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27Sep2013

U-454

A-312

D-377

O-381

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE INTERNAL SUPPORT DISC WITHIN THE DIESEL EXHAUST FLUID BACK PRESSURE VALVE ON CERTAIN RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS
108H 108K		PS44031

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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 "PS44031" 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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TERMINATION DATE

30Sep2015

PROBLEM

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The existing internal support disc within the Diesel Exhaust Fluid Valve on certain Retrofit Selective Catalytic Reduction Systems can fail. If the existing internal support disc fails, the Diesel Exhaust Fluid Valve can/will over dose SCR chamber with Diesel Exhaust Fluid and the system will not operate as designed.

AFFECTED PRODUCT

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Model	Identification Number
AFTERTREAT-SCR	ES700101, 105-170, 231-259, 266-273

PARTS NEEDED

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Qty	Part Number	Description
1	4487104	DISC-SUPPORT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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Prior to Disassembly:
Remove/Turn off all power to the dosing cabinet.

Lock Out and Tag Out the master disconnect.
Follow all mandated safety rules.

Please refer to the attached Rework Procedure.

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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%
0-8000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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Early production dosing cabinets under went several changes with the Diesel Exhaust Fluid Back Pressure Valves that were installed at the factory. (A) Plastic Housing, (B) Stainless Steel Housing, and (C) Stainless Steel Body with Plastic Cap. Refer Image 1.1.1.

Identify the Diesel Exhaust Fluid Back Pressure Valve in the dosing cabinet, and proceed to the appropriate rework procedure below.

Remove the Diesel Exhaust Fluid Back Pressure Valve from dosing cabinet. Refer to Image 1.1.2.

Disassemble and replace the internal support disc. Refer to Image 1.1.3.

Reassemble valve and tighten the assembly screws 5 Nm ( 43 in lb ). Reinstall valve into dosing cabinet.

Once Diesel Exhaust Fluid Back Pressure Valve has been reinstalled, it is necessary
to set the back pressure valve at ~40 psi. This is an important adjustment. If the back pressure valve is set too low it will not be able to seal against the DEF head pressure, and can flood the reactor. If the valve is set two high, it can stop all flow of DEF, and will force DEF out the pump pressure release valve, possibly damaging the pump.

Procedure to Set Back Pressure Valve

Plastic Housing (A) or Stainless Steel Housing (B)

The field method of setting the valve is to back off the adjustment screw until the spring pressure is released, tighten the screw until contact is made with the spring, then tighten the screw two complete revolutions. The adjustment screw gives ~20 psi per revolution of the screw, so two turns sets it at about 40 psi.

Note: Special care should be taken when determining when the screw makes contact with the spring. Occasionally the screw can be tight, making it hard to determine when the screw makes contact with the spring. Lubricating the screw can help.

Stainless Steel Body with Plastic Cap (C)

The valve may be marked as BPM025SV50P. Refer to Image 1.1.4. If the spring has 9 coils (A), unscrew the white nylon adjustment screw until it is flush with the valve nose. Tighten the screw eight complete turns. This will set the valve at ~40 psi.

The valve may be marked as BPM025S1V. Refer to Image 1.1.4. If the spring has 7 coils (B), unscrew the white nylon adjustment screw until it is flush with the valve nose. Tighten the screw six complete turns. This will set the valve at ~40 psi.