PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE DIESEL PARTICULATE FILTER (DPF) SENSOR BOX MOUNTING HARDWARE ON CERTAIN C9, C13, AND C15 TRUCK ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE DIESEL PARTICULATE FILTER (DPF) SENSOR BOX MOUNTING HARDWARE ON CERTAIN C9, C13, AND C15 TRUCK ENGINES

Usage:

REBE3391-00

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30Jul2008

U-391

A-318

TT-23

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE DIESEL PARTICULATE FILTER (DPF) SENSOR BOX MOUNTING HARDWARE ON CERTAIN C9, C13, AND C15 TRUCK ENGINES
1091		PI31537

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31537" 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 "PI31537" 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
31Jan2009	31Jul2009

PROBLEM

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Diesel Particulate Filter (DPF) sensor box brackets need to be replaced on certain C9, C13, and C15 Truck Engines. The existing sensor box bracket can crack.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C13	LEE01108, 2953, 2959, 3378, 3524, 4976, 5218, 5265, 5493, 5778
C15	SDP01205, 1227, 2127, 2255, 2705, 4338, 4364, 4722

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*****Group 2*****
C13	LEE01118, 1317, 1849, 1964, 3461, 5826
C15	SDP01612, 4270, 4279, 4461, 4808, 5753

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*****Group 3*****
C13	LEE00537, 883, 885, 890, 892, 899, 1242, 2077

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*****Group 4*****
C13	LEE00866, 877, 1046-1051, 1056, 1066, 1068, 1114, 1134, 1182, 1240, 1298, 1515-1516, 1535, 1615, 1882, 1907, 1911, 1915, 1917, 1979, 2128, 2130-2131, 2415, 4122, 6749, 9058
C15	SDP00719, 777, 831, 835, 843, 846, 1173, 1189-1190, 1196, 1237, 1272, 1298, 1332, 2425, 2474, 2484, 2504, 8799, 8807

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*****Group 5*****
C9	C9S00829

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	1A5350	CLIP
1	3B4504	LOCKWASHER-1/4
1	5C9553	BOLT
1	2828222	STRAP-BAND
1	2920724	STRAP-SUPPORT
1	3113342	BRACKET AS.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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*****
1	1A5350	CLIP
1	3B4504	LOCKWASHER-1/4
1	5C9553	BOLT
1	2828222	STRAP-BAND
1	2920724	STRAP-SUPPORT
1	3113342	BRACKET AS.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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*****
1	1A5350	CLIP
1	3B4504	LOCKWASHER-1/4
1	5C9553	BOLT
1	2828222	STRAP-BAND
1	2920724	STRAP-SUPPORT
1	3239159	BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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 4*****
1	1A5350	CLIP
1	3B4504	LOCKWASHER-1/4
1	5C9553	BOLT
1	2828222	STRAP-BAND
1	2920724	STRAP-SUPPORT
1	3092476	BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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 5*****
1	1A5350	CLIP
1	3B4504	LOCKWASHER-1/4
1	5C9553	BOLT
1	2828222	STRAP-BAND
1	2924848	STRAP-SUPPORT
1	3092476	BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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Remove and replace the DPF sensor box bracket. Refer to the attached Rework Procedure.

NOTE: Where applicable, the DPF pressure sensor line update Service Letter REBE3397 may be performed in conjuction with this Service Letter.

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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 2.0-hour job for Group 1
Dealer to perform most economical repair. Description____________________________SMCS Code___Hours Wash___________________________________1091-074____.3 Remove and install sensor box and sen._1091-010_____1.2 Test after repair______________________1091-030_____.5

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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 2.0-hour job for Group 2
Dealer to perform most economical repair. Description____________________________SMCS Code___Hours Wash___________________________________1091-074____.3 Remove and install sensor box and sen._1091-010_____1.2 Test after repair______________________1091-030_____.5

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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 2.0-hour job for Group 3
Dealer to perform most economical repair. Description____________________________SMCS Code___Hours Wash___________________________________1091-074____.3 Remove and install sensor box and sen._1091-010_____1.2 Test after repair______________________1091-030_____.5

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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 2.0-hour job for Group 4
Dealer to perform most economical repair. Description____________________________SMCS Code___Hours Wash___________________________________1091-074____.3 Remove and install sensor box and sen._1091-010_____1.2 Test after repair______________________1091-030_____.5

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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 2.0-hour job for Group 5
Dealer to perform most economical repair. Description____________________________SMCS Code___Hours Wash___________________________________1091-074____.3 Remove and install sensor box and sen._1091-010_____1.2 Test after repair______________________1091-030_____.5

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 REPLACING THE DIESEL PARTICULATE FILTER (DPF) SENSOR BOX MOUNTING HARDWARE ON CERTAIN C9, C13, AND C15 TRUCK ENGINES

MODELS INVOLVED - C9, C13, AND C15 TRUCK ENGINES

Dear Caterpillar Product Owner:

The Diesel Particulate Filter (DPF) sensor box bracket needs to be replaced on the products listed below. The existing sensor box bracket can crack. 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 30Jul2008 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 30Jul2008 Service Letter

Rework Procedure

1) Wash debris from Diesel Particulate Filter (DPF) sensor box assembly as necessary.
2) Remove the DPF sensor box, pressure lines, and thermocouples from the DPF center section per the appropriate Disassembly and Assembly manual.

Image1.1.1

3) Remove the sensor box bracket and heat shield from the sensor box. Keep the bolt hardware for re-use.

Image1.2.1

4) Install new sensor box bracket and existing heat shield. Tighten all 6 bolts to a torque of 12 +/- 3 Nm (106 +/- 27 lb-in).

Image1.3.1

5) Where applicable perform the DPF sensor line update, Service Letter REBE3397 at this step.
6) Install sensor box, pressure lines, and thermocouples onto DPF.

NOTE: Reference appropriate Disassembly and Assembly manual for proper torque and use of anti-seize.

Image1.4.1

7) Start the engine and use CAT ET to ensure that the status parameter Diesel Particulate Trap #1 Differential Pressure has a value greater than zero. Also ensure status parameters Diesel Particulate Trap #1 Intake Temperature, and Diesel Particulate Trap #1 Outlet Temperature show reasonable values and increase with the rising exhaust temperatures.