CONTROL GP 9W2126 - Caterpillar

REBE3160-01
14Jan2008
(Revised 28Jan2008)
U-29
A-26
O-25
TT-4
Before/After
PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST COMBUSTION GROUPS ON CERTAIN 2007 C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN SISU CHASSIS
1901 PS42603
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 "PS42603" as the Part Numberand "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.
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.
This Revised Service Letter replaces the 14Jan2008 Service Letter. Changes have been made to Service Claims Allowance.
TERMINATION DATE
31Jan2010
PROBLEM
The combustion group ARD body material may be subjected to temperatures that are high enough to degrade prematurely.
AFFECTED PRODUCT
Model Identification Number
C15 B5R00153, 156-160, 173-195, 199-213, 215-216, 219, 221, 223, 225-226, 228-234
PARTS NEEDED
Qty
Part Number Description
4 3E4352 WASHER-HARD
7 9X8267 WASHER
1 2840671 CLAMP-V-BAND
7 2840761 BOLT-HEX HEAD
2 2890728 NUT-HEX
2 2903930 BOLT-HEX HEAD
5 2914454 SPACER
5 2915204 LOCKNUT-HEX FLG
5 2934967 STUD-TAPERLOCK
2 2967780 GASKET
1 3038533 TUBE AS.-AIR
1 3041024 SHIELD-HEAT
1 3041025 SHIELD-HEAT
1 3110872 BODY-MACHINED
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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
Replace the exhaust combustion group. Refer to the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-250000 miles,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 8.0-hour job
This work is being done proactive and should be considered "before failure" warranty claim description code "56".
Dealer to perform most economical repair.
Description___________________SMCS Code______Hours
Wash__________________________107P-074_______0.3
Troubleshooting/ECM Download__107P-035_______0.6
ECM Flash_____________________1901-591_______0.5
Perform rework procedure______108B-010_______6.6
Exception may be allowed depending on chassis type.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Refer to apporpriate Service Manual as necessary.
1. Remove combustion body group (ARD) by referencing RENR9706 "Combustion Body Group (ARD) - Removal Procedure".
2. Remove the ARD extension pipe assembly.
3. Install 304-1024 and 304-1025 Heat Shields on the new 311-0872 ARD Body with 284-0761 Bolts and 9X-8267 Washers. Tighten to a torque of 12 +/- 1 Nm. (Image 1.1.1)
Image1.1.1
Image1.1.2
4. Install combustion head group (ARD) by following steps 1-3 in media RENR9706 "Combustion Head Group (ARD) ? Installation Procedure".
5. Install combustion body group (ARD) by referencing media RENR9706 "Combustion Body Group (ARD) ? Installation Procedure".
6. Replace ARD combustion air tube assembly with replacement PN 303-8533.
7. Assemble the flared end of extension pipe assembly to the combustion group body with a new OEM supplied V-band Clamp. Do not tighten clamp at this time.
9. Align extension pipe with chassis exhaust pipe. Do not tighten OEM supplied v-band clamp at this time.
10. Inspect for interferences with chassis or other components and align piping as necessary.
11. Tighten the OEM supplied v-band clamp that connects