PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST COMBUSTION GROUPS ON CERTAIN 2007 C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN SISU CHASSIS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST COMBUSTION GROUPS ON CERTAIN 2007 C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN SISU CHASSIS

Usage:

REBE3160-01

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14Jan2008

(Revised 28Jan2008)

U-29

A-26

O-25

TT-4

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST COMBUSTION GROUPS ON CERTAIN 2007 C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN SISU CHASSIS
1901		PS42603

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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 "PS42603" 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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NOTE:	This Revised Service Letter replaces the 14Jan2008 Service Letter. Changes have been made to Service Claims Allowance.

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TERMINATION DATE

31Jan2010

PROBLEM

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The combustion group ARD body material may be subjected to temperatures that are high enough to degrade prematurely.

AFFECTED PRODUCT

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Model	Identification Number
C15	B5R00153, 156-160, 173-195, 199-213, 215-216, 219, 221, 223, 225-226, 228-234

PARTS NEEDED

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Qty	Part Number	Description
4	3E4352	WASHER-HARD
7	9X8267	WASHER
1	2840671	CLAMP-V-BAND
7	2840761	BOLT-HEX HEAD
2	2890728	NUT-HEX
2	2903930	BOLT-HEX HEAD
5	2914454	SPACER
5	2915204	LOCKNUT-HEX FLG
5	2934967	STUD-TAPERLOCK
2	2967780	GASKET
1	3038533	TUBE AS.-AIR
1	3041024	SHIELD-HEAT
1	3041025	SHIELD-HEAT
1	3110872	BODY-MACHINED
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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

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Replace the exhaust combustion group. Refer to the attached Rework Procedure.

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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%
0-250000 miles, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 8.0-hour job
This work is being done proactive and should be considered "before failure" warranty claim description code "56". Dealer to perform most economical repair. Description___________________SMCS Code______Hours Wash__________________________107P-074_______0.3 Troubleshooting/ECM Download__107P-035_______0.6 ECM Flash_____________________1901-591_______0.5 Perform rework procedure______108B-010_______6.6 Exception may be allowed depending on chassis type.

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PARTS DISPOSITION

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

Rework Procedure

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Refer to apporpriate Service Manual as necessary.

1. Remove combustion body group (ARD) by referencing RENR9706 "Combustion Body Group (ARD) - Removal Procedure".

2. Remove the ARD extension pipe assembly.

3. Install 304-1024 and 304-1025 Heat Shields on the new 311-0872 ARD Body with 284-0761 Bolts and 9X-8267 Washers. Tighten to a torque of 12 +/- 1 Nm. (Image 1.1.1)

Image1.1.1

Image1.1.2

4. Install combustion head group (ARD) by following steps 1-3 in media RENR9706 "Combustion Head Group (ARD) ? Installation Procedure".

5. Install combustion body group (ARD) by referencing media RENR9706 "Combustion Body Group (ARD) ? Installation Procedure".

6. Replace ARD combustion air tube assembly with replacement PN 303-8533.

7. Assemble the flared end of extension pipe assembly to the combustion group body with a new OEM supplied V-band Clamp. Do not tighten clamp at this time.

9. Align extension pipe with chassis exhaust pipe. Do not tighten OEM supplied v-band clamp at this time.

10. Inspect for interferences with chassis or other components and align piping as necessary.

11. Tighten the OEM supplied v-band clamp that connects the extension pipe to the combustion group body according to OEM specifications using a new clamp.

12. Tighten the OEM supplied v-band clamp that connects the extension pipe to the chassis exhaust according to OEM specifications using a new clamp.

13. Flash Engine Electronic Control Module with the latest software according to SIS web. If SIS web is not available then contact the Truck Engine Call Center. (1-800-477-4986)

14. Perform ARD ignition test in CAT ET.