PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ALTERNATOR BRACKET AND THE AIR INLET HEATER ON CERTAIN C9 ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ALTERNATOR BRACKET AND THE AIR INLET HEATER ON CERTAIN C9 ENGINES

Usage:

SEBE9168-02

May 5, 2005
(Revised December 2005)
U-142
TT-6

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ALTERNATOR BRACKET AND THE AIR INLET HEATER ON CERTAIN C9 ENGINES
1408		PI30804

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30804" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI30804" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "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 May 5, 2005 (Revised June 2005) Service Letter. Changes have been made to the Parts Needed.

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COMPLETION DATE	TERMINATION DATE
November 30, 2005	May 31, 2006

PROBLEM

Faulty alternator brackets are generating cracks. Also the air inlet heater relay may fail.

AFFECTED PRODUCT

****Group 1****

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Model	Identification Number
C9	MTB105, 109-190, 197-1001, 1003, 1005, 1007-1014, 1016-1090, 1092-1145, 1147-1221, 1227-1387, 1396-1429, 1431-1432, 1434-1464, 1467

****Group 2****

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Model	Identification Number
C9	MTB1-1485

PARTS NEEDED

****Group 1****

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Qty	Part Number	Description
1	2179010	SUPPORT AS.
1	2201174	BRACKET AS
1	2399804	TUBE AS
1	2469363	BRACKET AS.
1	2678554	SUPPORT-ALT
1	2275904	SEAL
2	8T4182	BOLT

****Group 2 ****

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Qty	Part Number	Description
1	2234453	SWITCH AS-MT

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

****Group 1****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	4.0	0	0	0	0
NOTE: This is a 4.0 hour job which also includes test and wash. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

****Group 2****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	1.0	0	0	0	0
NOTE: This is a 1.0 hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Special Note:

Return all 223-4453 relays to:

Caterpillar Inc.
Service Claims Room
Attn: Cat Electronics Service Engineer
8201 N. University
Peoria, IL 61615 MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE ALTERNATOR BRACKET AND THE AIR INLET HEATER

MODELS INVOLVED ? CERTAIN C9 ENGINES

Dear Caterpillar Product Owner:

Your Caterpillar Engine needs to have the alternator bracket or the air inlet heater replaced. Some engines may require both to be changed. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated May 5, 2005 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to May 5, 2005 Service Letter

Rework Procedure

****Group 1****

Loosen and remove belt

Remove upper bracket as. (220-1174 or 246-9363) depending on bus. Discard

Remove the 4 idler pulleys from support as. (217-9010)

Remove support as. (217-9010) Discard (lifting eye will also be removed from head).

Remove drain hose (bottom of alternator to front cover)

This would consist of tube as. (239-9804) and hose (236-1803). Remove all as one unit from bottom of alternator to front cover. Discard the tube as. (239-9804) Plug hole on bottom of alternator

Remove reinforced flexible fuel line (just on the fuel base side)

Remove primary fuel line (fuel filter to head)

Remove fuel line (HEUI pump to fuel filter)

Remove filter base (in order for support as. {267-8554} to come out)

Remove bolt from top of crankcase breather cap, move breather off to the side

Remove low pressure oil line (HEUI pump to block)

Remove high pressure oil line (HEUI pump to top rail on head)

Disconnect solenoid on top of HEUI pump

Remove HEUI pump

Discard used o-ring seal (HEUI pump to front housing)

Remove support as. (267-8554) Discard (strap alternator above for support)

Reassemble the components in the reverse order, using the new components as out lined in the "PARTS NEEDED"