PRODUCT SUPPORT PROGRAM FOR REPLACING THE ALTERNATOR BRACKET, AIR INLET HEATER SOLENOID, OIL FILL TUBE, AND WATER TEMPERATURE REGULATOR ON CERTAIN C9 ON-HIGHWAY MASS TRANSIT BUS ENGINES
Usage:
REBE1864-00
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| 11May2007 |
H330
H335
H335
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| After Failure Only (Limited distribution) | PRODUCT SUPPORT PROGRAM FOR REPLACING THE ALTERNATOR BRACKET, AIR INLET HEATER SOLENOID, OIL FILL TUBE, AND WATER TEMPERATURE REGULATOR ON CERTAIN C9 ON-HIGHWAY MASS TRANSIT BUS ENGINES |
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| 1207 1408 1900 1803 5502 1316 1393 1355 1380 | PS51292 |
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| NOTE: | This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51292" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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 |
| 30Nov2007 |
PROBLEM
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| The existing alternator bracket, air inlet heater solenoid, oil fill tube, and water temperature regulator may fail and need replaced on certain C9 on-highway Mass Transit Bus engines. |
AFFECTED PRODUCT
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| Model | Identification Number |
| C9 | MTB01000, 1005, 1007-1014, 1016-1078, 1087-1090, 1093-1095, 1097, 1099, 1101, 1103-1104, 1109-1110, 1117-1129, 1131-1134, 1136, 1140-1141, 1143-1144, 1147, 1149-1150, 1159-1162, 1172-1176, 1180-1181, 1183-1184, 1186, 1188, 1190, 1192-1193, 1196, 1199-1201, 1205, 1208, 1217, 1221, 1227-1230, 1232-1233, 1235, 1240-1241, 1244-1245, 1249-1252, 1255, 1261-1263, 1267, 1269, 1272-1273, 1278, 1285, 1287-1288, 1293, 1298, 1301-1303, 1306, 1311-1318, 1320-1322, 1324-1329, 1332-1343, 1345-1349, 1351-1353, 1355-1363, 1365-1366, 1368, 1371-1372, 1374, 1380-1381, 1384-1386, 1396, 1398-1400, 1402, 1404, 1406, 1409, 1411, 1415, 1418, 1420-1421, 1425-1426, 1428-1429, 1431-1432, 1434-1444, 1447-1451, 1455-1456, 1537 |
PARTS NEEDED
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Qty |
Part Number | Description |
| 2 | 8T4182 | BOLT-HEX HEAD |
| 1 | 0619455 | SEAL-O-RING |
| 1 | 2095582 | SWITCH AS-MAGC |
| 1 | 2179010 | SUPPORT AS. |
| 1 | 2192340 | GASKET |
| 1 | 2201174 | BRACKET AS |
| 1 | 2275904 | SEAL-O-RING |
| 1 | 2399804 | TUBE AS |
| 1 | 2495737 | TUBE AS-OIL FILL |
| 1 | 2678554 | SUPPORT-ALT |
| 1 | 2845421 | REGULATOR-WATER |
ACTION REQUIRED
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| See the attached Rework Procedure. |
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SERVICE CLAIM ALLOWANCES
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| NOTE: This is a 1.0-hour job | ||||||
| Dealer to perform the most economical repair option. Depending on option(s) chosen in letter some jobs will exceed 1.0 hour. Exception maybe be considered and claimed depending on chassis type. OPTION 1 Description___________________SMCS______Hours R & I Air Inlet Heater______1090-010_____0.7 R & I Alternator____________1405-010_____0.8 R & I Alternator Bracket____1405-010-BK__0.2 R & I HEUI Pump_____________1714-010_____1.1 HEUI Pump Test After________1714-030_____0.5 HEUI Troubleshoot___________1714-035_____1.2 Wash________________________1714-074_____0.3 OPTION 2 Description___________________SMCS______Hours R & I Thermostat____________1355-010_____0.8 Thermostat Test After_______1355-030_____0.5 Wash________________________1355-074_____0.3 OPTION 3 Description___________________SMCS______Hours R & I Oil Filler____________1316-010_____0.2 Wash________________________1316-074_____0.3 |
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PARTS DISPOSITION
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| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
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| Follow the procedures and specifications given in RENR7559, Disassembly and Assembly for C9 Urban Transit Bus Engines. OPTION 1 Failure(s): Alternator bracket can develop cracks and fail. Air inlet heater relay solenoid can fail and cause the inlet heater to not function properly and provide a check engine light warning. Repair: - Loosen and remove belt. - Remove and discard Upper Bracket As. (220-1174 or 246-9363) depending on bus. - Remove the 4 idler pulleys from Support As. (217-9010). - Remove and discard Support As. (217-9010). (lifting eye will also be removed from head). - Remove drain hose (bottom of alternator to front cover) consisting 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 and 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". - Replace the Inlet Air Heater Switch (209-5582). - Test and wash. OPTION 2 Failure: Water temperature regulator can fail causing an overcooling condition to the engine. Repair: - Remove the current Water Temperature Regulator (115-4223 or 119-3025) and replace with a new 284-5421 Water Temperature Regulator. OPTION 3 Failure: Oil fill tube can leak past the seal. Repair: - Install updated Tube As - Oil Fill (249-5737) and O-ring (061-9455). |
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