PRODUCT SUPPORT PROGRAM FOR INSPECTING CERTAIN MODEL YEAR 2007 HEAVY DUTY TRUCK ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING CERTAIN MODEL YEAR 2007 HEAVY DUTY TRUCK ENGINES

Usage:

REBE1813-00

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16Apr2007

U-144

A-121

O-130

TT-10

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSPECTING CERTAIN MODEL YEAR 2007 HEAVY DUTY TRUCK ENGINES
1000 1290 1408 1900		PS42386

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NOTE:

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 "PS42386" as the Part Number and "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.

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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.

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TERMINATION DATE

31Oct2007

PROBLEM

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The existing wiring routing on these engines can cause pre-mature sensor failures caused by melting wires. The existing clamps on the Caterpillar Regeneration System (CRS) Combustion Air Delta P Sensor can cause inaccurate mass air flow readings.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C15	SDP01743-01746, 1748-1768, 1770-1790, 1792-1801, 1803-1845, 1847-1879, 1881, 1883-1958, 1960-1974, 1976-1993, 1995-2012, 2014, 2016-2052, 2054-2079, 2081-2137, 2141-2145, 2147-2154, 2158

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*******Group 2*******

C13

LEE01000-01001, 1007, 1017-1026, 1028-1031, 1033-1037, 1039, 1041-1074, 1076-1107, 1109-1135, 1153-1196, 1198, 1201-1224, 1226-1228, 1230-1233, 1235-1237, 1239-1242, 1244-1245, 1247-1291, 1293, 1295, 1297-1311, 1313-1315, 1318, 1321-1325, 1327-1356, 1358-1359, 1366-1369, 1371-1373, 1376, 1378-1386, 1388-1406, 1409-1421, 1423-1426, 1428, 1432-1436, 1438-1442, 1444-1446, 1449-1450, 1452-1462, 1464-1472, 1474-1484, 1486, 1488-1493, 1495-1496, 1500-1502, 1504-1506, 1508, 1511, 1513, 1515-1530, 1532-1536, 1539-1545, 1550-1553

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*****Group 3*****
C15	SDP01100-01101, 1103-1118, 1129-1168, 1173-1187, 1189-1202, 1204-1211, 1213-1216, 1220-1221, 1223-1225, 1227-1260, 1262-1290, 1292-1305, 1307-1315, 1317-1322, 1324-1429, 1431-1477, 1484-1502, 1504-1526, 1528-1556, 1558-1622, 1624-1678, 1680-1683, 1685-1742

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
4	1P4278	CLAMP-HOSE
*****Group 2*****
4	1P4278	CLAMP-HOSE
*****Group 3*****
4	1P4278	CLAMP-HOSE
1	3S2093	STRAP-CABLE

ACTION REQUIRED

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All trucks located on dealer lots or currently in service should follow the rework procedure below.

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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%
*****Group 1*****
0-50000 miles, 0-6 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.2-hour job for Group 1

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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%
*****Group 2*****
0-50000 hrs, 0-6 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.2-hour job for Group 2

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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%
*****Group 3*****
0-50000 hrs, 0-6 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.2-hour job for Group 3

PARTS DISPOSITION

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

Rework Procedure

Step 1: All Groups

Reference the 2007 Wiring Harness Guide at https://truck.cat.com/cda/layout?m=262&x=7 When using this document, look up the correct engine arrangement number and verify that the CRS sensor wires are routed correctly. If the sensors are not routed correctly, perform the repair using the parts provided for that specific engine arrangement. Make sure that none of the sensor leads will be in contact with hot engine components or rubbing on sharp edges.

If the engine has already been put in service, insure damage to the sensor has not occurred. If damage has occurred replace the appropriate part(s) and route per the above document.

Step 2: All Groups (Image 1.2.1)

Remove the four spring type hose clamps from the CRS Combustion Air Delta P Sensor and replace with 1P-4782 hose clamps with a torque of 1 N-m. When installing the new clamps, make sure the tubes are aligned correctly and are not pinched in any area. Reference Illustration 1 below, the C15 sensor is in a similar position. This sensor is located at the top right hand side of the engine and has two tubes connected to the 1? combustion air tube. Also insure steel sensor line fittings are torqued to 16 N-m at the combustion air tube connection.

Image1.2.1

Step 3: Group 3 Only (Image 1.3.1 and 1.3.2)

Remove the engine valve cover in order to inspect the injector wiring harness around cylinder number 5 and 6. Install tie strap P/N 3S-2093 as shown in illustration number 1.3.1. The harness should be routed and secured as shown in illustration 1.3.2. Visually inspect all other areas and verify wires are not interfering with components that can rub through the wiring harness

Image1.3.1

Image1.3.2

Step 3A: Group 3 Only (Image 1.4.1 and 1.4.2)

Install 8mm of P/N 119-3662 heat shrink tubing over front and rear injector harness bolts. Stretch the heat shrink with needle nose pliers to aid in installing over the bolt. Use a heat gun to melt the heat shrink around the bolt as seen in Image 1.4.2.

Image1.4.1

Image1.4.2

Step 4: All Groups

Inspect all CRS fuel, air, oil and coolant lines for rub points on the engine. Perform a visual inspection of all hard lines for interference issues.

Key areas to inspect are:

1. All oil lines supplying oil to the CGI actuator and CRS combustion air valve.
2. CRS fuel lines from the CRS head to the fuel manifold, which is located next to the valve cover base.
3. Inspect the purge air pump lines that supply air to the CRS system.
4. CRS coolant lines
5. All sensor connections for proper wire orientation. The sensor wires should not be bent in over causing excessive pull on the wires. If any of these are found, remove the zip tie, correct the wire and re-apply a zip tie.

Step 5: All Groups

Download a warranty report and upload it to SIMS with the service letter number in the comment field.

If defects are found and additional time is necessary, supply supporting documentation when submitting the claim.