PRODUCT SUPPORT PROGRAM FOR UPDATING THE ENGINE SOFTWARE AND POSSIBLY REPLACING THE DEF MANIFOLD ON CERTAIN C4.4 INDUSTRIAL ENGINES, XQ115, AND XQ125 GENERATOR SETS
Usage:
TEBE8525-01
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| 10Dec2018 |
| (Revised 12Apr2019) |
U-688
A-499
D-611
O-604
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| After Failure Only | PRODUCT SUPPORT PROGRAM FOR UPDATING THE ENGINE SOFTWARE AND POSSIBLY REPLACING THE DEF MANIFOLD ON CERTAIN C4.4 INDUSTRIAL ENGINES, XQ115, AND XQ125 GENERATOR SETS |
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| 108H 1920 | PS53914 |
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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 "PS53914" 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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| NOTE: | This Revised Service Letter replaces the 10Dec2018 Service Letter. Changes have been made to the Affected Product, Action Required, and Service Claim Allowances. |
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TERMINATION DATE |
| 31Dec2020 |
PROBLEM
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| The existing DEF Manifold can fail to communicate DEF level, DEF temperature and DEF quality on certain C4.4 Industrial Engines, XQ115, and XQ125 Generator Sets. If failure occurs the engine ECM will generate fault code 1235-9 along with the associated inducement code 5246-0. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| C4.4 | JKT00013, 16, 32, 47, 49, 55-58, 64, 68-69, 80, 85, 87-91, 105-106, 193, 209-213, 249-253, 255-257, 303-308, 370, 404-412, 428-432, 459-464, 467-476, 533-536, 618-624, 655, 669, 689, 836-837, 839-843, 864-879, 887-888, 891, 912-914, 949-951, 985, 991-1013, 1025-1027, 1046, 1107-1114, 1125-1133, 1147-1152, 1190-1191, 1193, 1222-1226, 1231-1236, 1396-1400, 1408-1422, 1443-1444, 1448-1463, 1467-1477, 1486-1489, 1510-1513, 1515, 1517-1526, 1549, 1552, 1556-1561, 1566-1567, 1661-1662, 1688-1715, 1717-1728, 1731-1734, 1751-1757, 1796-1798, 1804, 1840-1842, 1861, 1879-1881, 1886-1906, 1915-1936, 1946-1956, 1964, 1974, 2003-2016, 2022-2024, 2033-2062, 2070-2071, 2080-2105, 2107-2150, 2152-2159, 2172-2177, 2200, 2202-2205, 2331-2340, 2364-2367, 2390-2392, 2398-2401, 2407, 2432-2434, 2442, 2475-2478, 2483-2488, 2511-2521, 2576-2602, 2643-2644, 2649-2653, 2656, 2663-2686, 2722-2726, 2728-2747, 2755-2778, 2782, 2784-2796, 2798, 2819-2823, 2829-2832, 2838-2849, 2852-2855, 2863-2868, 2871-2876, 2880-2885, 2984-2985, 2992, 3000-3003, 3010-3014, 3062-3071, 3073-3074, 3076-3088, 3094-3097, 3124-3142, 3295-3296, 3307, 3360-3371, 3383-3404, 3459, 3462-3464, 3508-3516, 3554-3556, 3568, 3603-3617, 3641-3643, 3679-3681, 3706, 3713, 3733, 3769-3804, 3844-3845, 3853-3857, 3864-3866, 3898-3905, 3914-3916, 3918-3923, 3947-3948, 3960, 3964, 3967-3979, 3989, 4003-4004, 4013-4018, 4026-4029, 4031-4050, 4091-4099, 4103-4115, 4124-4129, 4167-4168, 4176-4177, 4179, 4263, 4286-4292, 4303-4304, 4320-4346, 4376-4383, 4387-4391, 4408-4412, 4456, 4496-4500, 4531-4542, 4549-4562, 4565-4571, 4573, 4597-4601, 4618-4620, 4626-4627, 4646-4653, 4663-4664, 4678-4679, 4699-4720, 4737-4754, 4770-4797, 4801-4802, 4823-4831, 4843, 4879-4882, 4921-4925, 4927-4948, 4964-4965, 4983-4985, 5006-5010, 5074-5076, 5082-5091, 5141-5143, 5148-5150, 5172-5182, 5186-5189, 5207, 5233-5242, 5245, 5256-5271, 5273-5288, 5300-5314, 5348-5375, 5400, 5426-5429, 5463-5473, 5480-5489, 5516-5527, 5565-5566, 5570-5571, 5587, 5595-5598, 5602-5608, 5639-5644, 5651, 5657, 5683-5689, 5700-5710, 5756-5758, 5778-5784, 5790-5796, 5807, 5835, 5837-5840, 5873, 5915, 5923-5935, 5945-5950, 5969-5971, 6060-6073, 6077-6092, 6094-6105, 6145-6159, 6204-6205, 6216-6222, 6237, 6336-6350, 6362, 6395-6397, 6450-6475, 6478, 6493-6498, 6501-6503, 6519-6527, 6604-6625, 6655-6658, 6660-6661, 6699-6701, 6729-6740, 6818-6820, 6834-6838, 6840, 6842-6861, 6900-6907, 6939-6941, 6962-6970, 6975-6976, 7027-7044, 7046-7058, 7083-7084, 7090, 7093-7119, 7140-7141, 7158-7162, 7198-7205, 7227, 7229-7244, 7281-7286, 7292-7299, 7335-7340, 7345-7353, 7355-7359, 7370-7381, 7400-7402, 7407-7413, 7416-7419, 7425-7444, 7454-7458, 7502-7506, 7536-7547, 7550-7553, 7561-7566, 7599, 7609-7619, 7626-7632, 7638-7659, 7679-7698, 7709-7720, 7724-7733, 7754-7773, 7805-7806, 7814-7817, 7825-7836, 7854-7859, 7904, 7917-7919, 7921-7923, 7939-7940, 7959-7968, 7970, 8019-8025, 8053-8061, 8176-8195, 8211-8224, 8287-8291, 8293-8297, 8315-8316, 8358-8364, 8369-8373, 8403-8409, 8423-8425, 8428-8433, 8462-8463, 8476-8492, 8500, 8528-8531, 8542-8549, 8568-8573, 8619-8624, 8634-8639, 8684, 8707, 8709-8710, 8712-8716, 8729-8734, 8764-8765, 8783-8788, 8848, 8855, 8911-8912, 8925-8927, 8975-8990, 9021, 9080-9088, 9090-9091, 9106, 9158 |
| XQ115 | CF700100 |
| XQ125 | CK500100, 102-105, 107, 110, 143-332, 334-335, 337, 341 |
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| *******Group 2******* | |
| C4.4 | JKT00011, 14, 17-18, 20, 27-31, 33-46, 48, 50-54, 59-63, 76-79, 81-84, 86, 100-103, 129-144, 149-162, 176, 190-192, 238, 241, 254, 258, 309-315, 326, 465-466, 553-560, 584-587, 609-617, 625, 627, 688, 690-693, 720, 754, 774-776, 803, 807-811, 832-834, 880-886, 892-896, 915, 952-955, 961, 977, 983-984, 986-990, 1014-1024, 1028-1034, 1045, 1047-1073, 1085-1095, 1106, 1134-1137, 1192, 1206, 1217-1221, 1230, 1267, 1291-1292, 1335, 1406-1407, 1447, 1514, 1527-1529, 1550-1551, 1553-1555, 1562-1565, 1643, 1654-1660, 1716, 1729-1730, 1735-1740, 1758-1764, 1795, 1799-1803, 1818-1820, 1838-1839, 1872-1878, 1882-1885, 1907-1914, 1937-1945, 1957-1963, 1965-1973, 1987-2002, 2017-2021, 2025-2032, 2063-2069, 2072-2079, 2106, 2151, 2160-2171, 2180-2196, 2206-2216, 2255-2266, 2268-2269, 2291-2298, 2304-2307, 2329-2330, 2341-2346, 2360-2362, 2368, 2393-2397, 2402-2406, 2443, 2455-2459, 2474, 2479-2482, 2500, 2523-2532, 2534-2550, 2561-2575, 2603, 2615, 2621, 2628-2642, 2647-2648, 2657-2660, 2687-2690, 2696-2703, 2715-2721, 2752-2754, 2797, 2799-2818, 2824-2828, 2833-2837, 2850-2851, 2869-2870, 2877-2879, 2886-2932, 2953-2959, 2979-2983, 2993-2999, 3004-3009, 3015-3056, 3060-3061, 3072, 3075, 3119-3123, 3143-3155, 3166-3178, 3180-3189, 3206-3217, 3231, 3233-3235, 3241-3248, 3263-3271, 3289-3294, 3325-3326, 3339-3344, 3359, 3372-3378, 3405-3414, 3438-3447, 3451-3458, 3460-3461, 3465-3466, 3499-3507, 3537-3542, 3552, 3557-3562, 3584-3585, 3587, 3602, 3618-3619, 3621-3630, 3632-3640, 3659-3678, 3707-3712, 3714-3722, 3734-3736, 3756-3761, 3763-3768, 3805-3814, 3846-3852, 3906-3913, 3917, 3949-3958, 3961-3963, 3965-3966, 3999-4002, 4005-4012, 4030, 4116-4123, 4169-4171, 4173-4175, 4178, 4188-4198, 4209-4210, 4273-4274, 4316-4319, 4357-4366, 4384-4386, 4392-4393, 4413-4417, 4457-4461, 4482-4483, 4488-4495, 4530, 4563-4564, 4572, 4574-4596, 4616-4617, 4621-4625, 4642-4645, 4654-4662, 4680, 4721-4727, 4735-4736, 4755-4769, 4798-4800, 4803-4808, 4811-4814, 4816-4822, 4832-4842, 4861, 4863, 4874-4878, 4883-4886, 4888-4897, 4899, 4920, 4926, 4966-4974, 4978-4982, 4986-4992, 5011-5030, 5037-5043, 5058, 5072-5073, 5077-5081, 5094-5095, 5099, 5144-5147, 5183-5185, 5190-5206, 5208-5232, 5243-5244, 5246-5247, 5249-5255, 5272, 5299, 5343-5347, 5377-5386, 5401-5406, 5474-5479, 5490-5515, 5556-5564, 5568-5569, 5572-5574, 5576-5586, 5588-5594, 5600-5601, 5652-5656, 5658-5682, 5735-5755, 5759-5763, 5776-5777, 5813-5826, 5829-5834, 5836, 5841, 5874-5891, 5904-5914, 5916-5922, 5973-5992, 5994-5995, 6008-6059, 6074-6076, 6093, 6106-6115, 6160-6168, 6170-6182, 6190-6195, 6199-6203, 6206-6215, 6223-6236, 6238-6244, 6272-6286, 6294-6296, 6305-6307, 6354, 6356-6361, 6363-6394, 6398-6399, 6425-6444, 6446-6449, 6476-6477, 6479-6492, 6499, 6504-6509, 6518, 6541-6550, 6580-6603, 6626, 6687-6698, 6741-6750, 6762-6817, 6821-6822, 6832-6833, 6841, 6886-6899, 6928-6938, 6971-6974, 6977-6992, 7013-7026, 7045, 7091-7092, 7135-7139, 7153-7157, 7213-7226, 7245-7256, 7287-7291, 7330-7334, 7341-7344, 7360-7369, 7391-7393, 7424, 7476-7501, 7559-7560, 7567-7576, 7582-7593, 7600-7608, 7620-7625, 7633-7637, 7699-7708, 7721-7723, 7734-7753, 7774-7791, 7808-7813, 7818-7824, 7837-7839, 7841-7853, 7860-7864, 7874-7891, 7902-7903, 7905-7916, 7920, 7924, 7941-7945, 7956-7958, 7969, 8026-8041, 8047-8052, 8091-8132, 8155-8175, 8196-8210, 8225-8227, 8272-8279, 8285-8286, 8298-8314, 8345-8357, 8366-8368, 8374-8402, 8410-8422, 8426-8427, 8434-8443, 8493-8499, 8501-8514, 8567, 8588-8595, 8602-8613, 8667-8683, 8685-8689, 8691, 8697-8706, 8723-8728, 8778-8782, 8840-8847, 8858-8869, 8879-8910, 8930-8935, 8946-8949, 9012-9020, 9022-9026, 9045-9054, 9148-9150, 9152-9153, 9155-9157, 9164, 9166-9167 |
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| *******Group 3******* | |
| C4.4 | JKT00002-00007, 9, 15, 21-26, 65-67, 70-75, 92-99, 104, 107-128, 145-148, 163-175, 177-189, 194-208, 214-237, 239-240, 242-248, 259-302, 316-325, 327-369, 371-403, 413-427, 433-458, 477-532, 537-546, 548-552, 561-583, 588-608, 626, 628-654, 656-667, 670-687, 694-719, 721-753, 755-773, 777-802, 804-806, 812-831, 835, 838, 844-863, 889-890, 897-911, 916-948, 956-960, 962-976, 978-982, 1035-1044, 1074-1084, 1096-1105, 1115-1124, 1138-1146, 1153-1189, 1194-1205, 1207-1216, 1237-1266, 1268-1290, 1293-1334, 1336-1395, 1401-1405, 1423-1442, 1464-1466, 1478-1485, 1490-1509, 1530-1548, 1568-1642, 1644-1653, 1663-1687, 1741-1750, 1765-1794, 1805-1817, 1821-1837, 1843-1860, 1862-1871, 1975-1986, 2217-2254, 2270-2287, 2289-2290, 2308-2328, 2352, 2363, 2369-2389, 2408-2431, 2435-2441, 2444-2453, 2460-2472, 2489-2499, 2501-2510, 2522, 2551-2560, 2604-2610, 2612-2614, 2616-2620, 2622-2627, 2645-2646, 2654-2655, 2661-2662, 2691-2695, 2704-2714, 2727, 2748-2751, 2779-2781, 2856-2862, 2933-2952, 2960-2978, 2986-2991, 3057-3059, 3098-3103, 3109-3118, 3156-3165, 3190-3200, 3218-3230, 3232, 3249-3262, 3297-3306, 3308-3317, 3321-3324, 3327, 3330, 3332-3334, 3345-3358, 3415-3437, 3448-3450, 3467-3498, 3517-3536, 3543-3551, 3553, 3569-3583, 3644-3658, 3692-3705, 3815-3843, 3858-3863, 3867-3877, 3924-3936, 3959, 3985-3988, 3990-3998, 4019-4025, 4051-4060, 4071-4080, 4100-4102, 4130-4164, 4180-4187, 4211-4224, 4226-4262, 4264-4272, 4285, 4293-4302, 4306-4315, 4347-4356, 4367-4375, 4394-4407, 4418-4455, 4462-4481, 4484-4487, 4501-4529, 4543-4548, 4602-4615, 4628-4641, 4665-4677, 4681-4688, 4844-4860, 4868-4870, 4903-4904, 4906-4919, 4949-4963, 4993-5005, 5031-5036, 5044-5057, 5059-5071, 5107-5140, 5151-5171, 5289-5298, 5315, 5319-5320, 5322-5323, 5325-5326, 5329, 5333, 5341, 5430-5437, 5609-5612, 5645-5650, 5690-5699, 5808-5812, 5827-5828, 5892-5903, 5993, 5996-6007, 6183-6189, 6196-6198, 6287-6293, 6297-6304, 6351-6352, 6528-6540, 6659, 6662-6686, 6751-6761, 6823-6831, 6908-6911, 6942-6961, 7003, 7120-7134, 7187-7197, 7209-7212, 7228, 7382-7389, 7394-7399, 7403-7406, 7414-7415, 7420-7423, 7507-7535, 7548, 7554-7558, 7577-7581, 7594-7598, 7946-7955, 8042-8046, 8250-8259, 8574-8587, 8766-8777, 8824-8839, 9027-9038 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 1 | 4623232 | MANIFOLD GP-CONT (If Needed) |
| 1 | ENGSOFTWARE | ENGINE SOFTWARE |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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. |
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| *******Group 2******* | ||
| 1 | 4623219 | MANIFOLD GP-CONT (If Needed) |
| 1 | ENGSOFTWARE | ENGINE SOFTWARE |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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. |
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| *******Group 3******* | ||
| 1 | 4623610 | MANIFOLD GP-CONT (If Needed) |
| 1 | ENGSOFTWARE | ENGINE SOFTWARE |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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. |
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ACTION REQUIRED
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| 1. Upon arrival at the product ensure that the DEF system (including tank and lines) is fully thawed and at least half full of DEF. 2. If the product is reporting two or more of the following codes (1761-17, 1761-18 and 1761-1) at the same timestamp alongside the active inducement code 5246-0 without reporting 5392-31, this is an indication that the level is being incorrectly reported due to software. 3. Update product with the latest engine software. Check SIS Web for the latest software version. 4. Operate the product for several minutes to confirm that the DEF level has responded, and the fault and inducement codes have cleared. 5. If fixed return the product to service, else proceed to step 6. 6. If the product is reporting error code 1235-9 along with the associated inducement code 5246-0 follow the Troubleshooting Guide to locate which node on CAN C is not communicating. Confirm that the ?Aftertreatment #1 DEF Tank Quality Sensor? is the fault. 7. Replace the DEF manifold. 8. Operate the product for several minutes to confirm fix. Then return the product to service. |
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SERVICE CLAIM ALLOWANCES
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