SUPPORT-ALTERNATOR 9N3164 - Caterpillar

SEBE8654-02 February 12, 2004
(Revised April 2004)
U-37
TT-5
beforeor
after failure PRODUCT SUPPORT PROGRAM FOR INSPECTIONOF CERTAIN C15 TRUCKS
1803 PS41546
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS41546"as the Part number and "7755" as the Group Number. If administered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If administered after failure, use "96" as theWarranty Claim Description Code and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe February 12, 2004 Service Letter (Revised March 2004). Changes havebeen made to the Rework Procedure.TERMINATION DATE
February 28, 2005PROBLEM
Certain C15 on-highway truck engines require inspectionsand repair of some components. This program should be conducted prior todelivery to the customer if possible. On the engines requiring inspectionand repair of the air compressor expansion chamber, failure to performthese procedures may result in an air compressor failure.AFFECTED PRODUCT
Model Identification Number
C15 BXS418-10836PARTS NEEDED
No parts needed.ACTION REQUIRED
See the 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
0-100,000
0-12 mos 100% 1.0 0 0 0 0
This is a 1.0?hr job.When claiming for this service letter, use the following SMCS codes andtimes:
SMCS Code Description Labor allowed
1803-035 Air Compressor Box - Inspect 0.5
None GeneralInspection 0.5PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.Attach. (1-Rework Procedure)Rework Procedure
Inspect air compressor check valve expansion chamber(air box), and clean if necessary. See Illustration 1 below.
Failure to perform this procedurecan result in an air compressor failure.
The tank assembly may contain certain types ofdebris that could damage the air compressor. Examples of debris may includeweld berries, mig welding wire, etc. To inspect the air compressor checkvalve air box, do the following:
Remove the tank from the engine.
Inspect hose and tubing for debris, and cleanas necessary.
Remove the reed valve cover plate from the tank,and ensure the reed valve cover plate gasket is not damaged.
If the reed valve cover plate gasket IS damaged,replace it.
If the reed valve cover plate gasket IS NOT damaged,reuse it.
Inspect the inside of the tank for debris.
Chase a tap, bolt or fitting through all threadedbosses at least twice to free up any machining debris, and blue loctite.
Using emery cloth, dislodge any remaining debrison the inside of the air box and around the threaded bosses.
Use a screwdriver, metal chisel, or magnet toremove any remaining debris.
Blow out air box using compressed air.
Clean the inside of the air box with an oily clothor shop towel.
Reassemble with loctite product number 242 (referenceCAT part number 4C4030) on reed valve cover plate bolts.
Illustration 1
Inspect high-pressure turbocharger mounting nuts.
Inspect each 2384665 turbo mounting stud to makesure it has the correct 1687800 Nut. See Illustrations 2 and 3 below.
If the correct nut is found, no further actionis needed
If a stud is found to have an incorrect nut, thenthe nut and stud need to be replaced.
All four studs need