PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CLEAN GAS INDUCTION VENTURI MASS AIR FLOW SENSOR AND THE CRANKCASE VENTILATION SYSTEM ON CERTAIN C13 AND C15 ON-HIGHWAY TRUCK ENGINES. Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CLEAN GAS INDUCTION VENTURI MASS AIR FLOW SENSOR AND THE CRANKCASE VENTILATION SYSTEM ON CERTAIN C13 AND C15 ON-HIGHWAY TRUCK ENGINES.

Usage:

REBE1865-00

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22Jun2007

U-283

A-229

TT-18

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CLEAN GAS INDUCTION VENTURI MASS AIR FLOW SENSOR AND THE CRANKCASE VENTILATION SYSTEM ON CERTAIN C13 AND C15 ON-HIGHWAY TRUCK ENGINES.
1071 1061 1317 1439		PI31293

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31293" 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 "PI31293" as the Part Number, "7751" as the Group Number, "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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COMPLETION DATE	TERMINATION DATE
31Dec2007	30Jun2008

PROBLEM

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The Clean Gas Induction Venturi Mass Air Flow Sensor must be replaced on all units listed. Additional units listed will also require the installation of a Crank Case Ventilation System. Once this rework is completed these units will be able to be serviced with current certified software.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C15	B5R00154-00155 SDP00774, 776-777, 779, 781-784, 796, 802-809, 811, 813-814, 816-818, 820-822, 825, 827, 831, 834-835, 838, 843, 846-847, 856, 858-859, 862, 865, 871-872, 874, 883

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*****Group 2*****
C15	SDP00775, 778, 780, 785-795, 797-799, 823-824, 828-830, 832-833, 836-837, 839-842, 844-845, 848-853, 855, 857, 860-861, 863-864, 866-867, 873, 876, 879-882, 884-887

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*****Group 3*****
C13	LEE00815-00818, 820-842, 844, 846-847, 850-851, 853-856, 858, 860, 862, 864-865, 871-873, 877-881, 886, 893-894, 898, 900, 902

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*****Group 4*****
C13	LEE00845, 848-849, 852, 859, 861, 863, 867, 883-885, 887-892, 895, 897, 899, 901

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*****Group 5*****
C13	LEE00866

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*****Group 6*****
C15	SDP00719-00724

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*****Group 7*****
C15	SDP00800-00801, 810, 815, 819, 826, 854

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	0S1588	BOLT
1	0S1594	BOLT
4	1P4278	CLAMP-HOSE
6	3S2093	STRAP-CABLE
2	4P8134	CLIP-LADDER
4	5M2894	WASHER-HARD
1	5P4939	SCREW-HEX FLANGE
1	6V5839	WASHER-HARD
1	6V5842	BOLT
1	6V8801	NUT
1	7C6591	CLAMP-FUEL LINE
1	7C7747	CLAMP-FUEL LINE
2	8M2772	CLIP
1	1921329	BOLT-SHOULDER
1	2062423	SADDLE
1	2338004	JOINT-EXPANSION
1	2396807	CLAMP AS-V-BAND
2	2412634	CLAMP-V-BAND
1	2803921	SENSOR-TEMP
1	2883834	TUBE-VENTURI
1	2964078	ELBOW-EXH
1	2964364	TUBE AS.-AIR
1	2964365	TUBE AS.-AIR
1	2965808	BRACKET
1	2981680	BRACKET
*****Group 2*****
2	0S1588	BOLT
1	0S1594	BOLT
1	0T0573	BOLT
4	1P4278	CLAMP-HOSE
1	3H5788	SPACER
6	3S2093	STRAP-CABLE
2	4P8134	CLIP-LADDER
4	5M2894	WASHER-HARD
1	5P4939	SCREW-HEX FLANGE
1	6V5839	WASHER-HARD
1	6V5842	BOLT
1	6V8801	NUT
1	7C6591	CLAMP-FUEL LINE
1	7C7747	CLAMP-FUEL LINE
2	8M2772	CLIP
1	1921329	BOLT-SHOULDER
1	2062423	SADDLE
1	2338004	JOINT-EXPANSION
1	2396807	CLAMP AS-V-BAND
2	2412634	CLAMP-V-BAND
1	2803921	SENSOR-TEMP
1	2883834	TUBE-VENTURI
1	2964078	ELBOW-EXH
1	2964364	TUBE AS.-AIR
1	2964365	TUBE AS.-AIR
1	2965808	BRACKET
1	2981680	BRACKET
*****Group 3*****
5	3S2093	STRAP-CABLE
2	4N9170	CLIP
1	4P7581	CLIP-LADDER
1	4P8134	CLIP-LADDER
1	5P0537	WASHER-HARD
1	5P7970	NUT
2	6V5219	BOLT
1	6V5839	WASHER-HARD
1	6V5842	BOLT
1	8T4224	WASHER-HARD
1	8T9364	BOLT
2	9M1974	WASHER-HARD
1	1921329	BOLT-SHOULDER
1	2338004	JOINT-EXPANSION
1	2396807	CLAMP AS-V-BAND
2	2412634	CLAMP-V-BAND
1	2803921	SENSOR-TEMP
1	2856395	CLIP
1	2883833	TUBE-VENTURI
1	2888580	CLAMP-CRS
1	2888581	CLAMP-CRS
1	2901993	STRAP-CABLE
1	2964077	ELBOW-EXH
1	2964395	TUBE AS.-AIR
1	2964396	TUBE AS.-AIR
1	2981679	BRACKET-SUPPORT
*****Group 4*****
1	1W9168	CLAMP
1	1W9169	CLAMP FUEL LINE
5	3S2093	STRAP-CABLE
1	4P7581	CLIP-LADDER
1	4P8134	CLIP-LADDER
1	5P4939	SCREW-HEX FLANGE
2	5P8347	BOLT
1	8S7499	PIN-SPRING
2	9M1974	WASHER-HARD
1	2338004	JOINT-EXPANSION
3	2412634	CLAMP-V-BAND
1	2801127	ELBOW-EXHAUST
1	2803921	SENSOR-TEMP
1	2901993	STRAP-CABLE
1	3077623	TUBE-VENTURI
1	3080744	CLAMP-V-BAND
1	3117847	ELBOW
1	3117848	TUBE AS.-AIR
1	3117849	TUBE AS.-AIR
*****Group 5*****
5	3S2093	STRAP-CABLE
2	4N9170	CLIP
1	4P7581	CLIP-LADDER
1	4P8134	CLIP-LADDER
1	5P0537	WASHER-HARD
1	5P7970	NUT
2	6V5219	BOLT
1	6V5839	WASHER-HARD
1	6V5842	BOLT
1	8T4224	WASHER-HARD
1	8T9364	BOLT
2	9M1974	WASHER-HARD
1	1921329	BOLT-SHOULDER
1	2338004	JOINT-EXPANSION
1	2396807	CLAMP AS-V-BAND
2	2412634	CLAMP-V-BAND
1	2803921	SENSOR-TEMP
1	2856395	CLIP
1	2883833	TUBE-VENTURI
1	2888580	CLAMP-CRS
1	2888581	CLAMP-CRS
1	2901993	STRAP-CABLE
1	2964077	ELBOW-EXH
1	2981679	BRACKET-SUPPORT
1	3023763	TUBE AS.-AIR
1	3023764	TUBE AS.-AIR
*****Group 6*****
1	0L1143	BOLT
1	0L2070	BOLT
2	0S1588	BOLT
1	0S1594	BOLT
1	0T0573	BOLT
2	1H3337	BOLT
1	1T0720	BOLT-12 POINT HD
1	3E4091	ELBOW-90 DEG
1	3E4352	WASHER-HARD
1	3H5788	SPACER
4	3S2093	STRAP-CABLE
1	4L6454	BOLT
2	4P8134	CLIP-LADDER
8	5M2894	WASHER-HARD
1	5P4939	SCREW-HEX FLANGE
2	5P9297	CLIP
1	5S0003	NUT-FULL
2	6G5608	CLAMP
1	6V3832	SEAL-O RING
3	6V3940	BOLT
1	6V5048	SEAL-O-RING
1	6V5839	WASHER-HARD
1	6V5842	BOLT
1	6V8801	NUT
1	7C6591	CLAMP-FUEL LINE
1	7C7747	CLAMP-FUEL LINE
2	8M2772	CLIP
1	8T1117	CLAMP-HOSE
2	8T4205	WASHER-HARD
3	9M1974	WASHER-HARD
2	9X6153	BOLT-SOCKET HD
1	9X8402	CLIP
2	1378101	SEAL-O-RING
2	1449973	CLAMP
1	1921329	BOLT-SHOULDER
1	2062423	SADDLE
1	2338004	JOINT-EXPANSION
1	2396807	CLAMP AS-V-BAND
2	2412634	CLAMP-V-BAND
1	2771873	CLIP-LADDER
1	2803921	SENSOR-TEMP
1	2883834	TUBE-VENTURI
1	2893891	CLIP
1	2946119	SENSOR
1	2964078	ELBOW-EXH
1	2964364	TUBE AS.-AIR
1	2964365	TUBE AS.-AIR
1	2965808	BRACKET
1	2965823	FILTER GP-FUMES
1	2975376	BRACKET-FILTER
1	2975378	TUBE AS.-OIL DR
1	2975387	HOSE-FUMES
1	2975392	ADAPTER-SENSOR
1	2975396	HOSE-FILTER INL
1	2981680	BRACKET
1	3005883	HOSE-OIL DRAIN
1	3009952	VALVE AS-CHECK
*****Group 7*****
4	0S1588	BOLT
1	0S1594	BOLT
1	0T0573	BOLT
1	1H3337	BOLT
1	3E4091	ELBOW-90 DEG
2	3E4352	WASHER-HARD
1	3H5788	SPACER
4	3S2093	STRAP-CABLE
2	4P8134	CLIP-LADDER
7	5M2894	WASHER-HARD
1	5P4939	SCREW-HEX FLANGE
2	5S0003	NUT-FULL
2	6G5608	CLAMP
1	6V3832	SEAL-O RING
4	6V3940	BOLT
1	6V5048	SEAL-O-RING
1	6V5839	WASHER-HARD
1	6V5842	BOLT
3	6V8801	NUT
2	7C4355	CLIP
1	7C6591	CLAMP-FUEL LINE
1	7C7747	CLAMP-FUEL LINE
2	8M2772	CLIP
2	8T0267	BOLT-SOCKET HEAD
2	8T1117	CLAMP-HOSE
1	8T4205	WASHER-HARD
2	8T4896	WASHER-HARD
1	8T9367	BOLT
4	9M1974	WASHER-HARD
2	1249633	CLIP
2	1378101	SEAL-O-RING
2	1449973	CLAMP
1	1921329	BOLT-SHOULDER
1	2062423	SADDLE
1	2338004	JOINT-EXPANSION
1	2396807	CLAMP AS-V-BAND
2	2412634	CLAMP-V-BAND
2	2771873	CLIP-LADDER
1	2803921	SENSOR-TEMP
1	2883834	TUBE-VENTURI
1	2893891	CLIP
1	2946119	SENSOR
1	2964078	ELBOW-EXH
1	2964364	TUBE AS.-AIR
1	2964365	TUBE AS.-AIR
1	2965808	BRACKET
1	2965823	FILTER GP-FUMES
1	2975377	BRACKET-FILTER
1	2975379	TUBE AS.-OIL DR
2	2975388	HOSE-FUMES
1	2975393	ADAPTER-SENSOR
1	2975397	HOSE-FUMES
1	2981680	BRACKET
1	3005886	HOSE-OIL DRAIN
1	3009952	VALVE AS-CHECK

ACTION REQUIRED

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This program requires a hardware update, a flashfile update (requiring a new interlock code), and a new Emissions/Certification Label. See attached Rework Procedure.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 5.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 5.0-hour job for Group 2

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 3.0-hour job for Group 3

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 6.0-hour job for Group 4

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 3.0-hour job for Group 5

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 6*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 7.0-hour job for Group 6

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 7*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 7.0-hour job for Group 7

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CLEAN GAS INDUCTION VENTURI MASS AIR FLOW SENSOR AND THE CRANKCASE VENTILLATION SYSTEM

MODELS INVOLVED - CERTAIN C13 AND C15 ON-HIGHWAY TRUCK ENGINES

Dear Caterpillar Product Owner:

The mass air flow sensor and the crankcase ventilation system needs to be updated on the products listed below. There are significant enhancements now available for these components. 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 22Jun2007 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 22Jun2007 Service Letter

Rework Procedure

Step 1. All Groups

Replace CGI Mass Air Flow Venturi and associated hardware. See image 1.1.1 for general hardware location reference. Refer to the table in image 1.1.2 for the proper group number being reworked. Reference the group number image on SISWeb for exact part location of the configuration being reworked.

Image1.1.1

Image1.1.2

Step 2. Group 6 and Group 7

Install Crankcase Ventilation System on all units listed in these groups. See image 1.2.1 for general hardware location reference. Refer to the table in image 1.2.2 for the proper group number being reworked. Reference the group number image on SISWeb for exact part location of the configuration being reworked.

Image1.2.1

Image1.2.2

Step 3. All Groups

Flash Engine Electronic Control Module (ECM) with new software. Software is available for all engines on SISWEb. Follow the Flash Over Procedure found on the Cat Truck Engine Website. The Flash Over Procedure can be found at following the link: https://truck.cat.com/cda/layout?m=262&x=7 and selecting the Flash Over Procedure link located under the 2007 ACERT header. This document MUST be used to ensure all configurable parameters are programmed correctly. Some engine systems may not function correctly if the Flash Over Procedure is not completed.

The technician MUST download new injector trim files and program them after the ECM flash is complete.

Refer to the tables in Image 1.3.1 and 1.3.2 for the correct new software part number, interlock code, and test spec.

Image1.3.1

Image1.3.2

Step 4.

Install New Regulatory Decal and Serial Number Identification Plate on Engine.
New Regulatory Decal can be requested from the Cat Truck Engine website at: https://truck.cat.com/cda/layout?m=37062&x=7