PRODUCT SUPPORT PROGRAM FOR INSPECTION OF CERTAIN C15 TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTION OF CERTAIN C15 TRUCKS

Usage:

SEBE8654-02

February 12, 2004
(Revised April 2004)
U-37
TT-5

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR INSPECTION OF CERTAIN C15 TRUCKS
1803		PS41546

NOTE: This Program can 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 "PS41546" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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.

NOTE: This Revised Service Letter replaces the February 12, 2004 Service Letter (Revised March 2004). Changes have been made to the Rework Procedure.

TERMINATION DATE

February 28, 2005

PROBLEM

Certain C15 on-highway truck engines require inspections and repair of some components. This program should be conducted prior to delivery to the customer if possible. On the engines requiring inspection and repair of the air compressor expansion chamber, failure to perform these procedures may result in an air compressor failure.

AFFECTED PRODUCT

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Model	Identification Number
C15	BXS418-10836

PARTS NEEDED

No parts needed.

ACTION REQUIRED

See the Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-100,000 0-12 mos	100%	1.0	0	0	0	0
NOTE: This is a 1.0?hr job.

When claiming for this service letter, use the following SMCS codes and times:

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SMCS Code	Description	Labor allowed
1803-035	Air Compressor Box - Inspect	0.5
None	General Inspection	0.5

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin 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.

NOTE: Failure to perform this procedure can result in an air compressor failure.

The tank assembly may contain certain types of debris that could damage the air compressor. Examples of debris may include weld berries, mig welding wire, etc. To inspect the air compressor check valve air box, do the following:

Remove the tank from the engine.
Inspect hose and tubing for debris, and clean as 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 threaded bosses at least twice to free up any machining debris, and blue loctite.
Using emery cloth, dislodge any remaining debris on the inside of the air box and around the threaded bosses.
Use a screwdriver, metal chisel, or magnet to remove any remaining debris.
Blow out air box using compressed air.
Clean the inside of the air box with an oily cloth or shop towel.
Reassemble with loctite product number 242 (reference CAT part number 4C4030) on reed valve cover plate bolts.

Illustration 1

Inspect high-pressure turbocharger mounting nuts.

Inspect each 2384665 turbo mounting stud to make sure it has the correct 1687800 Nut. See Illustrations 2 and 3 below.

If the correct nut is found, no further action is needed
If a stud is found to have an incorrect nut, then the nut and stud need to be replaced.
All four studs need to be checked.

Illustration 2

Illustration 3

3) When the procedure is complete, stamp the letters "E8" to the right of the engine serial number plate on the cylinder block to signify that this rework has been completed.