PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST ROCKER ARMS AND IN SOME CASES VARIABLE VALVE ACTUATOR (VVA) STUDS ON CERTAIN MXS AND NXS C15 ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST ROCKER ARMS AND IN SOME CASES VARIABLE VALVE ACTUATOR (VVA) STUDS ON CERTAIN MXS AND NXS C15 ENGINES

Usage:

REBE2843-03

02May2008

(Revised 17Mar2009)

U-229

A-185

D-181

O-205

TT-13

*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST ROCKER ARMS AND IN SOME CASES VARIABLE VALVE ACTUATOR (VVA) STUDS ON CERTAIN MXS AND NXS C15 ENGINES
1123 1921 1102		PS51487

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 "PS51487" 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.

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 02May2008 (Revised 02Oct2008) Service Letter. Changes have been made to Termination Date, Service Claims Allowance, Action Required, and Parts Disposition.

TERMINATION DATE

31Jul2009

PROBLEM

The existing exhaust rocker arm may fail at the first thread of the adjusting screw or the VVA stud may fail on certain MXS and NXS C15 engines.

AFFECTED PRODUCT

Model	Identification Number
*****Group 1*****
C15	MXS84933-85101, 85103-85193, 85195-85296, 85298-85357, 85359-85423, 85425-85434, 85436-85683, 85685-85839, 85841-85885, 85887-86068, 86070-86076, 86078-86144, 86146-86417, 86419-86427, 86429-86470, 86472-86876, 86878-87224, 87226-87279, 87281-87488, 87490-87554, 87556-87610, 87612-88019, 88021-88049, 88051-88825, 88827-88833, 88835-88902, 88904-89074, 89076-89204, 89206-89617, 89619-90390, 90392-90636, 90638-90729, 90731-91107, 91109-91314, 91316-91566, 91568-91884, 91886-91887, 91889-92353, 92355-92981, 92983-93302, 93304-93884, 93886-93977, 93980-94113, 94115-94181, 94183-94536, 94538-94539, 94541-94572, 94574-94686, 94689-94799, 94801-95044, 95046-95324, 95326-95370, 95372-95445, 95447-95565, 95567-95587, 95589-95887, 95889, 95893-95898, 95900-95902, 95904-95907, 95909, 95911, 95913-95915, 95917-95919, 95921, 95923, 95927-95929, 95931-95933, 95935-96029, 96031-97102, 97104-97106, 97108-97112, 97114, 97116, 97118-97828, 97830-98373, 98375-98510, 98512-98753, 98755-99187, 99999 NXS00100-00416, 418-511, 513-575, 577-788, 790-947, 949-1190, 1192-1276, 1278-1553, 1555-1808, 1810-1811, 1813-1815, 1819-1820, 1822, 1824-1831, 1833-1835, 1838-1839, 1841-1842, 1844-1845, 1847-1896, 1898, 1900, 1903, 1905, 1907, 1909-1914, 1916, 1918-1922, 1924-1931, 1933, 1936-1937, 1939, 1941-1949, 1951-1961, 1963, 1966-1967, 1969, 1971, 1973-1985, 1989-2001, 2005, 2007-2018, 2020-2021, 2023-2025, 2027-2040, 2042-2061, 2063-2064, 2069-2070, 2074-2075, 2077-2086, 2088-2101, 2103-2105, 2107, 2113-2125, 2127-2136, 2139-2140, 2143-2144, 2147-2164, 2166-2167, 2169-2176, 2178-2185, 2188, 2190, 2193-2194, 2197-2199, 2201-2203, 2207-3396, 3398-3415, 3417-3703, 3705-4190, 4192-4345, 4347-4449, 4451-4623, 4625-4734, 4736-5088, 5090-5097, 5099-5432, 5434-5444, 5446-5675, 5677-5844, 5846-5900, 5902-5946, 5948-5981, 5983-6259, 6261-6347, 6350-6368, 6370-6373, 6375-6443, 6445-6453, 6455-6558, 6560-6607, 6609-6732, 6734, 6736-6781, 6783-6990, 6992-7077, 7079-7103, 7105-7135, 7137-7145, 7147-7303, 7305-7336, 7338-7348, 7350-7378, 7380-7463, 7465-7466, 7468-7489, 7491-7595, 7597-7638, 7640-7643, 7646-7834, 7837-7941, 7943-8032

*****Group 2*****
C15	MXS25318-28217, 28219-28301, 28303-28319, 28321-28332, 28334-30850, 30852-30892, 30894-40922, 40924-43002, 43006-43503, 43505-52735, 52737-56020, 56022-57024, 57028-61023, 61026-61028, 61030-61035, 61037-61272, 61275-67024, 67026-67491, 67493-70561, 70563-77983, 77985-80137, 80139-80244, 80246-80266, 80269-80277, 80279-84932

*******Group 3*******

C15

MXS00300-00317, 319-322, 324, 326-327, 329-330, 332-353, 355-557, 559-564, 566-586, 588-874, 876-1038, 1040-1080, 1082-1194, 1196, 1199-1278, 1280-1751, 1753-1925, 1927-1998, 2000-2096, 2098-2502, 2504-2532, 2534-2585, 2587-2631, 2633-2634, 2636, 2638-2641, 2647, 2652, 2656, 2658, 2660, 2662-2674, 2676, 2678-2681, 2685-2693, 2695-2696, 2698-2699, 2701, 2703, 2705, 2708, 2717, 2723-2727, 2734, 2738, 2758-2760, 2762-2774, 2776-2779, 2781-2804, 2806-2807, 2810-2828, 2832, 2834, 2836, 2838, 2842, 2845, 2847, 2850, 2854, 2856, 2863, 2865-2866, 2868, 2870-2875, 2878, 2880-2886, 2888, 2890, 2892-2894, 2896, 2900, 2906, 2908, 2910, 2912, 2914-2915, 2918, 2924, 2927, 2929-2930, 2933, 2937, 2939, 2941, 2945, 2947, 2949-2950, 2952-2953, 2955, 2957, 2960-2975, 2977, 2980-3024, 3027-3042, 3044, 3046-3085, 3087-3099, 3101-3103, 3105-3106, 3108-3109, 3111-3115, 3117-3119, 3123, 3125-3127, 3132-3137, 3139-3140, 3145, 3147, 3149, 3152-3153, 3155-3157, 3164-3180, 3182-3400, 3402-3573, 3575, 3577-3631, 3633-3678, 3680-3840, 3842-3895, 3897-4059, 4061-4070, 4072-4289, 4291-4339, 4341-4418, 4421-4676, 4678-5024, 5026-5219, 5221-5373, 5375-5552, 5554-5559, 5562-5702, 5706-5950, 5952-5970, 5972-6082, 6084-6157, 6159-6240, 6242-6264, 6266, 6268-6347, 6349-6451, 6453, 6455-6459, 6461-6477, 6479-6627, 6629-6694, 6696-6780, 6782-6810, 6813, 6816, 6820, 6822-6836, 6838-6979, 6981, 6985-7148, 7150, 7152-7153, 7156, 7158-7173, 7175-7319, 7321-7348, 7351, 7353-7359, 7361-7372, 7374-7854, 7856-8049, 8051-8089, 8091-8163, 8166-8182, 8185-8246, 8252-8258, 8261-8708, 8710-9096, 9098-9154, 9157-9160, 9162-9375, 9377-9425, 9427-9661, 9663-10022, 10024-10468, 10470-10506, 10508-10735, 10737-11334, 11336-11447, 11449-11496, 11498-11535, 11537-11580, 11582-11623, 11625-12512, 12514-13214, 13216-13276, 13278-13399, 13401-13424, 13426-13569, 13571-13585, 13587, 13589-13612, 13614-14236, 14238-14762, 14764-14903, 14905-14996, 15000-15142, 15144-15434, 15436-15517, 15519-15549, 15551-15834, 15836-15838, 15840-16033, 16036-16271, 16273-16670, 16673-16681, 16683-16797, 16799-16929, 16931-17117, 17119-17133, 17135-17141, 17143-17311, 17313-17326, 17328-17334, 17336-17404, 17406-17425, 17427-17428, 17430-17503, 17505-17507, 17509-17639, 17641-17670, 17672-17701, 17703, 17705-17706, 17708-17853, 17855-17926, 17928-17934, 17937-17984, 17986-18326, 18328-18347, 18349-18350, 18353-18356, 18358-18487, 18489-19651, 19664-19813, 19815-19868, 19870-19871, 19873-19914, 19916-20111, 20113-20160, 20162, 20164-20558, 20560-20569, 20571-20782, 20784-20786, 20788-20797, 20799-21082, 21084-21169, 21171-21313, 21315-21355, 21357-21467, 21469-21689, 21691-21916, 21919, 21921-22262, 22264-22628, 22630-22840, 22842-23014, 23016-23118, 23120-23296, 23298-23522, 23525-23559, 23561-23756, 23759-23793, 23795-23947, 23949-24309, 24311-24387, 24389-24645, 24647-24669, 24671-24976, 24978-25112, 25114-25236, 25238-25317

PARTS NEEDED

Qty	Part Number	Description
*****Group 1*****
7	10R4708	ARM AS-V ROCKER
1	2566453	SENSOR-TEMP
9	3049553	STUD-6 PT HD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
7	10R4708	ARM AS-V ROCKER
1	2566453	SENSOR-TEMP
9	3049553	STUD-6 PT HD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 3*****
7	10R4708	ARM AS-V ROCKER
1	2644297	SENSOR-TEMP
9	3049553	STUD-6 PT HD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

Determine the proper repair based the failure mode.

Refer to Service Manual RENR9403, Disassembly and Assembly.
Refer to Special Instruction REHS3037, Inspection and Repair Procedure to Replace the Studs for Rocker Arm Shaft.

Labor for removal of broken studs is allowed based on supporting claim information.

Some options (other options are acceptable) for stud removal are: using left hand drill ( 1/4 in. drill - Cat part number 4C-3347); drill out and use an extractor (1/4 in drill and 4C-3367 extractor).

Reference documents for other removal information SMHS8297 Exhaust Stud Removal and REHS0302 3176 Broken Head Bolt Removal.

If a cylinder head is replaced as part of this repair, the claims story must provide a detailed description of the failure and the failure area on the head must be marked.

Group 1, Group 2, and Group 3.

For exhaust rocker arm failures:

- Replace all six exhaust rocker arms.
- Replace the intake rocker arm on the failed cylinder(s).
- Replace the inlet air temperature sensor.
- Replace all 9 VVA studs.

For VVA stud failure only:

- Replace all 9 VVA studs.
- Replace all 6 exhaust rocker arms.

SERVICE CLAIM ALLOWANCES

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*****
0-500000 miles, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.4-hour job for Group 1

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*****
0-500000 miles, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.4-hour job for Group 2 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Description SMCS Code Hours R & I Rocker Arm - Set__________________1123-010_______3.1 hrs. Troubleshooting_________________________1123-035_______0.6 hrs. Dealer may claim wash and test. Test after repair_______________________1123-030 ______0.3 hrs. Wash____________________________________1123-074 ______0.3 hrs. Exceptional labor may be claimed with proper documentation. Additional 0.1 hr will be allowed for replacing the inlet air temperature sensor. R & I Inlet Air Temperature Sensor_____1921-010_______0.1 hrs.

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*****
0-500000 miles, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.4-hour job for Group 3 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Description SMCS Code Hours R & I Rocker Arm - Set__________________1123-010_______3.1 hrs. Troubleshooting_________________________1123-035_______0.6 hrs. Dealer may claim wash and test. Test after repair_______________________1123-030 ______0.3 hrs. Wash____________________________________1123-074 ______0.3 hrs. Exceptional labor may be claimed with proper documentation. Additional 0.1 hr will be allowed for replacing the inlet air temperature sensor. R & I Inlet Air Temperature Sensor_____1921-010_______0.1 hrs.

PARTS DISPOSITION

Parts return requests will be issued through Send-It-Back for all claims over $4000.

CATERPILLAR_INC._-_MOSSVILLE____________
ROUTE_29_&_OLD_GALENA_ROAD______________
BLDG_DD,_DOCK_8,_ENG._PARTS_RETURN_AREA_
________________________________________
________________________________________
MOSSVILLE_____________________
ILLINOIS_______
UNITED_STATES_________________
61552__________