Diesel Exhaust Fluid (DEF) Pump on Certain C4.4 Engines {108U, 1439} Caterpillar

Asphalt Compactor

CB64B (S/N: C561-UP; 4781-UP)

CB66B (S/N: B661-UP)

CB68B (S/N: C681-UP)

CCS9 (S/N: C521-UP)

Asphalt Paver

AP500F (S/N: 4491-UP; F5M1-UP)

AP555F (S/N: AP51-UP; M451-UP)

AP600F (S/N: AP61-UP; D6F1-UP)

AP655F (S/N: 4521-UP; 4531-UP; MH61-UP)

Backhoe Loader

416F2 (S/N: HWB1-UP)

420F2 (S/N: NMB1-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)

440 (S/N: DC91-UP)

444F2 (S/N: HWS1-UP)

450 (S/N: KJH1-UP)

Compact Wheel Loader

910M (S/N: H221-UP)

914M (S/N: H241-UP)

918M (S/N: H261-UP)

Engine

C4.4 (S/N: CK51-UP; CF71-UP; JKT1-UP)

Excavator

312F (S/N: KMK1-UP)

313F (S/N: DH81-UP; DJE1-UP; NLG1-UP; PRG1-UP)

314F (S/N: LFC1-UP; RAF1-UP)

315F (S/N: FTC1-UP; TDY1-UP)

316F (S/N: XAD1-UP; YDL1-UP; ECZ1-UP)

318F (S/N: HCP1-UP; FFT1-UP)

320 (S/N: HEX1-UP)

320 GC (S/N: KTN1-UP)

320F (S/N: NHD1-UP; YBM1-UP)

323F (S/N: FA21-UP; YEC1-UP; MFY1-UP)

325F (S/N: XAA1-UP; YCA1-UP; CPF1-UP; NDJ1-UP; RBW1-UP)

Knuckleboom Loader

2384D (S/N: KP51-UP)

2484D (S/N: KP71-UP)

559D (S/N: KL51-UP)

579D (S/N: KL71-UP)

Mobile Hydraulic Power Unit

316F-MHPU (S/N: HS31-UP)

M316F MHPU (S/N: CP51-UP)

OEM Mobile Hydraulic Power Unit

323F OEM (S/N: P7P1-UP; RGP1-UP)

Pipelayer

PL61 (S/N: S3H1-UP)

Pneumatic Compactor

CW34 (S/N: AL31-UP)

Telehandler

TH3510D (S/N: TH21-UP)

TH357D (S/N: TD61-UP)

TH408D (S/N: TH91-UP)

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: EL71-UP; MGM1-UP; DFR1-UP; JTR1-UP)

Vibratory Asphalt Compactor

CB13 (S/N: PWP1-UP)

CB15 (S/N: M941-UP)

CB16 (S/N: HP51-UP)

Vibratory Soil Compactor

CP54B (S/N: 4831-UP; P541-UP)

CP56B (S/N: 4851-UP; P561-UP)

CP68B (S/N: P681-UP; 4891-UP)

CP74B (S/N: 4911-UP; P741-UP)

CS54B (S/N: 4821-UP; CS51-UP)

CS56B (S/N: 4841-UP; S561-UP)

CS64B (S/N: CW61-UP; 4861-UP)

CS66B (S/N: S661-UP; 4871-UP)

CS68B (S/N: CS81-UP; 4881-UP)

CS74B (S/N: 4901-UP; CS41-UP)

CS76B (S/N: 4921-UP)

CS78B (S/N: 4931-UP; S781-UP)

Wheeled Excavator

M314F (S/N: FB41-UP; F4A1-UP)

M315F (S/N: F4D1-UP)

M316F (S/N: FB61-UP; F6N1-UP)

M317F (S/N: F6P1-UP)

M323F (S/N: RH31-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

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Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Problem

There have been isolated instances where the Diesel Exhaust Fluid (DEF) pressure sensor within the DEF pump breaks and DEF leaks into the DEF pump. DEF wicks up the wiring between the DEF pump and the interface connector. The DEF then shorts across the pins of the connector leading to the issue.

Solution

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

1. Using an electronic service tool, generate a Product Status Report (PSR) with the engine running histograms and abnormal shutdown history included.

2. Check to see if the DEF system has been contaminated. Examples of contaminants are fuels, oils, coolant, and wind shield washer fluid.
   

   DEF Injector

3. Remove electrical connector and examine it for the presence of DEF.
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   Illustration 1	g06386447
   Typical example of a DEF injector (1) Location of the serial number (2) DEF injector (3) DEF injector electrical connector

   Note: Do not remove DEF injector from Clean Emissions Module (CEM).
   

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   Illustration 2	g06386460
   Typical example DEF injector electrical connector

   
   

4. Examine the OEM harness connection for the presence of DEF in the connector.
   

   31-Pin Connector

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   Illustration 3	g06386503
   Typical example of a 31-pin connector

5. Confirm that the 31-pin connector is securely tightened.
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   Illustration 4	g06386512
   Typical example of a 31-pin connector with blanking caps (4) Blanking caps

6. Ensure that blanking caps (4) are in place on the unused pins on both sides 31-pin connector.
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   Illustration 5	g06388958
   Typical example of a 31-pin connector O-Ring location

7. Disconnect 31-pin connector and ensure that the O-Ring is in the correct position in the machine side of the connection. Position (Y) shows where the red O-Ring seal is located.

8. Check for fluid contamination in the 31-pin connector. If contaminant is present, determine what the contaminant is. Check for DEF, which leaves white residue marks or the PH level (9 to 9.5).Check for diesel using HC strips. Check for water (PH 7).

9. Check for signs of overheating or corrosion.
   

   Machine Fuse

10. Inspect DEF fuse condition and the fuse rating.
    

    DEF Injector

11. Using a suitable multimeter, measure the electrical resistance on DEF injector connector pin 1 to pin 2. If the measured resistance is less than 6 Ohms or more than 8 Ohms, a fault in the injector is detected.

12. Check for signs of the presence of DEF within the machine electrical wires connected to the DEF injector.

13. Check the history of the machine for previous DEF injector issues.

14. Use the electronic service tool to generate a PSR and obtain an abnormal shutdown, engine running histograms, and application history.

15. Check for logged 3361-5 or 3821-5 "Aftertreatment #1 DEF Dosing Unit: Current Below Normal"diagnostic codes.

16. Using a suitable multimeter, measure the resistance between the following points:
    31-pin connector pin 11 and pin 2 DEF injector connector.
    31-pin connector pin 12 and pin 1 DEF injector connector.
    If the measured resistance is greater than 2 Ohms. There is an open circuit fault being indicated in the wiring between the 31-pin connector and the DEF injector.
    

    DEF Pump and Connector

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    Illustration 6	g06386836
    Typical example of the DEF pump and connector (5) Locking lever (6) DEF pump electrical connector

17. Ensure that the DEF pump electrical connector (6) is securely in place.

18. Slide back the yellow lever (5) to remove the electrical connector (6).
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    Illustration 7	g06386545
    Typical example of the DEF pump electrical connectors

19. Check for signs of fluid contamination in the DEF pump connector. Determine what the contaminant is. Check for DEF, which leaves white residue marks or the PH level (9 to 9.5).Check for diesel using HC strips. Check for water (PH 7).

20. Check for signs of overheating or corrosion.
    

    Machine Wiring

21. Inspect the machine wiring that is connected to the DEF system for possible shorts and deterioration of the insulation.

22. If required, install a replacement DEF pump. Refer to Disassembly and Assembly , Diesel Exhaust Fluid Pump - Remove and Install. Return the original DEF pump with the PSR through the Send It Back (SIB) for an open parts return request.

    After completing the steps above, generate a PSR using the electronic service tool. Ensure that PDF and XML versions are downloaded, with "Histogram" option selected in the download list.