CAP- 3796884 - Caterpillar

Rework Procedure
Make sure you have read and understood all of this document before beginning work.
Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator operation and disconnect/lockout all power sources before commencing any work. Ensure that the Air Supply pressure and DEF Supply pressure have been turned off going to the Dosing Cabinet.
1 - The 030-8110 Air supply fitting and 345-4080 DEF supply fitting need to be removed from the Dosing Cabinet to verify the proper O-rings are installed. The 030-8110 Air supply fitting should have (1) 6V-3250 O-ring installed and the 345-4080 DEF supply fitting should have (1) 3K-0360 O-ring installed. Replace any O-rings that are missing. Refer to Image 1.1.1.
Image1.1.1
The dosing pump can also develop a leak between the dosing pump head and DEF manifold due to an incorrect torque of the 8T-2396 bolts. These bolts can interfere with the washers that hold the dosing pump head to the dosing pump and cause a low torque value. Refer to Images 1.2.1 and 1.2.2.
Image1.2.1
Image1.2.2
Rework Procedure:
1 - Refer to SEBU8546 Operation and Maintenance Manual for Diesel Exhaust Fluid Pump removal. Once the pump is removed, inspect the washer location in reference to manifold bolt hole location. Reference Image 1.3.1 showing interference. Reference Image 1.3.2 showing no interference.
Image1.3.1
Image1.3.2
2 - If any of the manifold threaded holes show interference with the washers, the bolts will need to be loosened and the washers moved to one side to allow the proper clearance. Loosen bolt number 1 and use the special factory provided tool to insert between the pump head radius and the washers. Tighten bolt number 1 to 5.5 nm. Care should be taken to not over tighten these bolts. Repeat for bolts 2, 3 and 4 in sequence. Reference Images 1.4.1 and 1.4.2.
Image1.4.1
Image1.4.2
3 - If the washers will not move enough in order to gain the proper clearance, then there could be too much material on the pump head radius. This additional material will need to be ground out with a die grinder. Grind out just enough material to allow proper clearance.
Care must be taken to keep the pump clean if using a die grinder.
Refer to Images 1.5.1 for the area that would need to be ground out to allow the washers to move over enough to gain the proper clearance.
Image1.5.1
4 - Check the Dosing Pump check valves to ensure they are oriented correctly and have an 0-ring installed on each end of both check valves. If a check valve is missing an O-ring then the check valve will need to be replaced. Reference Image 1.6.1 for proper check valve orientation. Return any unused check