PRODUCT SUPPORT PROGRAM FOR RELOCATING THE 2380114 BOOST PRESSURE SENSOR IN CERTAIN 3054E ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR RELOCATING THE 2380114 BOOST PRESSURE SENSOR IN CERTAIN 3054E ENGINES

Usage:

SEBE9228-01

June 22, 2005
(Revised November 2005)
U-202
O-168

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR RELOCATING THE 2380114 BOOST PRESSURE SENSOR IN CERTAIN 3054E ENGINES
1917		PS41824

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 "PS41824" 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 June 22, 2005 Service Letter. Changes have been made to the Parts Needed Section.

TERMINATION DATE

June 30, 2007

PROBLEM

The existing mounting location of the 238-0114 boost pressure sensor exposes it to temperature ranges that can damage the sensor causing it to malfunction.

AFFECTED PRODUCT

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Model	Identification Number
3054E	30400704, 716-734, 848-864, 948- 952

PARTS NEEDED

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Qty	Part Number	Description
2	0676265	FERRULE
2	0358017	UNION
2	0676264	FITTING-FLAR
1	1590185	LOCTITE
2	1999252	HOSE AS
2	1999751	SEAL-O-RING
1	2163436	SENSOR GP-TE
1	2321295	PLUG-BLANKIN
1	2321322	PLUG-BLANKIN
1	2380114	SENSOR GROUP
1	2738681	BRECKET
1	2738687	TUBE

ACTION REQUIRED

The 238-0114 boost pressure sensor will be removed from its location in the inlet manifold to a mounting block that will connect by tubing to the inlet manifold providing an insulation gap. The air temp sensor will also be relocated to the new mounting block assembly.

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
0-1000 0-24 mos	100%	1.0	0	0	0	0
NOTE: This is a 1.0 hr job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure Installation instructions to be used in conjuntion with attached schematic.
Dis-assembly of factory installed parts:

Unclip wiring harness connections from inlet manifold sensors.
Remove sensors with "O" rings, retain for later reuse.
Remove rear side manifold blanking plate & discard.
Clean Loctite sealer residue away from machined face on inlet manifold where plate has been removed.

Sub-assemble Remote sensor bracket:

Tighten unions with an applied torque of 10Nm.
Place union nut & ferrule (2-off each) on each end of boost pipe.
Fit pipe into unions already screwed into bracket, be sure they are fully pushed in ensuring ferrules are seated. Tighten union nuts with applied torque 8Nm.

Assemble blanking plugs into cylinder head:

Fit yellow "O" ring onto M14 blanking plug, tighten with applied torque 10Nm.
Fit black "O" ring onto M18 blanking plug, tighten with applied torque 20Nm.

Note: Take care to ensure "O" rings are correctly seated on blanking plugs before fitting into cylinder head.

Assemble bracket onto cylinder head:

Apply a bead (3-4mm wide) of Loctite 5900 liquid sealer to the inlet manifold opening on a diameter of 80mm.
Fit bracket to head, secure with M8 screws (4-off previously removed) tighten with applied torque 22Nm.

Assemble sensor into remote bracket:

Take care to ensure "O" rings are correctly seated.
Locate sensors into respective tapped holes in bracket.
Tighten temperature sensor (Identify by probe, black "O" ring & M14 thread) with applied torque 20Nm.
Tighten boost pressure sensor (identify by yellow "O" ring & M14 thread) with applied torque 10Nm.
Connect wiring harness to sensors.

See photo?s below showing before & after modification.

Inlet manifold sensors installation before modification