PRODUCT SUPPORT PROGRAM FOR REPLACING THE DIESEL PARTICULATE FILTER (DPF) SENSOR BOX PRESSURE LINES ON CERTAIN C9, C13, AND C15 TRUCK ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE DIESEL PARTICULATE FILTER (DPF) SENSOR BOX PRESSURE LINES ON CERTAIN C9, C13, AND C15 TRUCK ENGINES

Usage:

REBE3397-00

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21May2008

U-275

A-224

TT-16

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE DIESEL PARTICULATE FILTER (DPF) SENSOR BOX PRESSURE LINES ON CERTAIN C9, C13, AND C15 TRUCK ENGINES
1091 1061		PS42705

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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 "PS42705" 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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TERMINATION DATE

31May2009

PROBLEM

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Diesel Particulate Filter (DPF) sensor box pressure lines need to be replaced on certain C9, C13, and C15 Truck Engines. The existing pressure lines may accumulate moisture due to condensation and cause regeneration problems.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C13	LEE00537, 883, 885, 890, 892, 899, 1242, 1422, 1448, 1559, 2077, 3141, 3577, 3586, 3613, 3620, 3846
C15	SDP02382

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*****Group 2*****
C9	C9S00547, 553, 557, 576, 591, 596, 607, 611, 615, 621, 660, 680, 793, 827, 829, 832, 880, 908, 1030

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*****Group 3*****
C13	LEE01108, 2933, 2953, 2959, 2980, 3378, 3524, 4318, 4752, 4770, 4782, 4788, 4794, 4924, 4976, 5065, 5218, 5223, 5265, 5336, 5493, 5730, 5778, 5831, 5847
C15	SDP01205, 1227, 1791, 2127, 2225, 2255, 2593, 2611, 2705, 2791, 4323, 4338, 4362, 4364, 4722, 4801, 6517, 6830, 6911

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*****Group 4*****
C13	LEE01118, 1294, 1317, 1331, 1807, 1813, 1849, 1964, 3461, 3467, 5406, 5826
C15	SDP01612, 4270, 4279, 4461, 4463, 4808, 4856, 5753, 6581

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*****Group 5*****
C15	SDP02371

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*****Group 6*****
C13	LEE00866, 877, 1046-1051, 1054, 1056, 1066, 1068, 1114, 1134, 1182, 1224, 1228, 1240, 1282, 1284, 1295, 1298, 1328, 1340, 1349, 1351, 1457-1458, 1465-1466, 1469, 1495, 1502, 1504, 1515-1516, 1520-1521, 1526, 1531, 1533, 1535, 1615, 1628, 1633, 1635, 1637, 1641, 1646, 1649, 1653, 1660, 1663-1664, 1698, 1759, 1763, 1781, 1882, 1907, 1911, 1915, 1917, 1973, 1979, 1983, 1992, 2008, 2023, 2029, 2044, 2047, 2051-2052, 2074, 2095-2096, 2101, 2112, 2124, 2128, 2130-2131, 2139, 2145, 2165, 2179, 2190, 2254, 2257, 2283, 2298, 2344, 2387, 2414-2415, 2464-2465, 2471, 2488, 2495, 2515-2516, 2522-2523, 2547, 2552, 2555, 2561, 2563, 2632, 2670, 2695, 2722, 2742, 2799, 2946, 2974, 2977, 3077, 3090, 3095, 3133, 3153, 3216, 3258, 3286, 3337, 3454, 3459, 3566-3567, 3585, 3652, 3711, 3754, 3764, 3830, 3837, 3857, 3885, 3916, 3946-3947, 3960, 3966-3967, 3969-3970, 3985, 4026-4027, 4032, 4042, 4049, 4074, 4091, 4098, 4122, 4242, 4244-4245, 4302, 4416, 4460, 4540, 4704, 4740, 4789, 4797, 4857, 4878, 4931-4932, 4970, 5044, 5049, 5052, 5055, 5060-5061, 5067, 5070, 5079, 5084, 5093, 5107, 5109, 5120, 5123, 5130, 5137, 5158, 6749
C15	SDP00719, 777, 831, 835, 843, 846, 1173, 1189-1190, 1196, 1237, 1272, 1298, 1332, 1527, 1738, 1764, 1776, 1936, 1947, 1967, 1981, 1995, 2035, 2081, 2152, 2189, 2204, 2213, 2251, 2265, 2267, 2348, 2354, 2425, 2434, 2474, 2484, 2504, 2543, 2552, 2661, 2669, 2744, 2825, 2842, 2853, 2857, 3008, 3113, 3142, 3151, 3248, 3295, 3333, 3414-3415, 3469, 3497, 3610, 3752, 3795, 3814, 3828, 3840, 3889, 3926, 3932, 4339, 4342, 4348, 4350, 4354, 4365, 4370, 4372, 4574, 4619, 4636, 4787, 4824, 4972-4973, 5101, 5121, 5154, 5206, 5243, 5259-5260, 5264, 5299, 5307, 5508, 5543, 5553, 5561, 5592, 5594, 5656, 5660-5661, 5682-5685, 5690, 5721, 5807, 6059, 6480, 6640, 6972, 8799

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*****Group 7*****
C13	LEE03188, 7063

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	2N8142	TEE-SWIVEL
1	4S4857	TEE
1	6V5048	SEAL-O-RING
1	7W3556	WASHER
4	2901993	STRAP-CABLE
1	3048042	CONNECTOR
1	3091912	TUBE AS.
1	3091913	TUBE AS
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.
*****Group 2*****
1	2N8142	TEE-SWIVEL
1	4S4857	TEE
1	6V5048	SEAL-O-RING
1	7W3556	WASHER
4	2901993	STRAP-CABLE
1	3048042	CONNECTOR
1	3189250	TUBE AS
1	3189251	TUBE AS
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.
*****Group 3*****
1	2N8142	TEE-SWIVEL
1	4S4857	TEE
1	6V5048	SEAL-O-RING
1	7W3556	WASHER
4	2901993	STRAP-CABLE
1	3048042	CONNECTOR
1	3091910	TUBE AS.
1	3091911	TUBE AS
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.
*****Group 4*****
1	2N8142	TEE-SWIVEL
1	4S4857	TEE
1	6V5048	SEAL-O-RING
1	7W3556	WASHER
4	2901993	STRAP-CABLE
1	3048042	CONNECTOR
1	3091910	TUBE AS.
1	3091911	TUBE AS
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.
*****Group 5*****
1	2N8142	TEE-SWIVEL
1	4S4857	TEE
1	6V5048	SEAL-O-RING
1	7W3556	WASHER
4	2901993	STRAP-CABLE
1	3048042	CONNECTOR
1	3091910	TUBE AS.
1	3091911	TUBE AS
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.
*****Group 6*****
1	2N8142	TEE-SWIVEL
1	4S4857	TEE
1	6V5048	SEAL-O-RING
1	7W3556	WASHER
4	2901993	STRAP-CABLE
1	3048042	CONNECTOR
1	3091908	TUBE AS.
1	3091909	TUBE AS
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.
*****Group 7*****
1	2N8142	TEE-SWIVEL
1	4S4857	TEE
1	6V5048	SEAL-O-RING
1	7W3556	WASHER
4	2901993	STRAP-CABLE
1	3048042	CONNECTOR
1	3102712	TUBE AS
1	3102713	TUBE AS.
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 DPF sensor box pressure lines. Refer to the attached Rework Procedure. This Service Letter may be performed in conjunction with REBE3391 where applicable.

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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%
*****Group 1*****
0-1000000 miles	100.0%	100.0%	0.0%	0.0%	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, rework, install________1091-010____1.2 Test after repair______________1091-030____.5

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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%
*****Group 2*****
0-1000000 miles	100.0%	100.0%	0.0%	0.0%	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, rework, install________1091-010____1.2 Test after repair______________1091-030____.5

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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%
*****Group 3*****
0-1000000 miles	100.0%	100.0%	0.0%	0.0%	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, rework, install________1091-010____1.2 Test after repair______________1091-030____.5

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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%
*****Group 4*****
0-1000000 miles	100.0%	100.0%	0.0%	0.0%	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, rework, install________1091-010____1.2 Test after repair______________1091-030____.5

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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%
*****Group 5*****
0-1000000 miles	100.0%	100.0%	0.0%	0.0%	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, rework, install________1091-010____1.2 Test after repair______________1091-030____.5

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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%
*****Group 6*****
0-1000000 miles	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 6
Dealer to perform most economical repair. Description____________________SMCS Code___Hours Wash___________________________1091-074____.3 Remove, rework, install________1091-010____1.2 Test after repair______________1091-030____.5

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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%
*****Group 7*****
0-1000000 miles	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 7
Dealer to perform most economical repair. Description____________________SMCS Code___Hours Wash___________________________1091-074____.3 Remove, rework, install________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.

Rework Procedure

1) Wash debris from Diesel Particulate Filter (DPF) as necessary.
2) Remove the DPF sensor box, pressure lines, and thermocouples from the DPF center section per the appropriate Disassembly and Assembly manual.
3) Remove the sensor box bracket and heat shield from the sensor box. Keep the bolt hardware for re-use.

Image1.1.1

4) Remove the 90 degree pressure line fitting under the sensor box.
5) Remove the 90 degree pressure line fitting from the DPF center section that is closest to the outlet side.
6) The new pressure line that will fit into the DPF center section will need to be installed into the port in which the thermocouple was fitted. The existing thermocouple will need to be fitted into the port in which the old pressure line was fitted.
NOTE: Swapping of the ports is only necessary on the outlet side of the center section.

Image1.2.1

Image1.2.2

7) Install the 7W-3556 washer on the 304-8042 straight fitting. Install the straight fitting into the DPF pressure port (towards the outlet side) in which the thermocouple was previously installed, tighten to a torque of 24 +/- 4 Nm (212 +/- 35 lb-in). Screw the 2N-8142 tee fitting onto that straight fitting and tighten to a torque of 24 +/- 4 Nm (212 +/- 35 lb-in).

Image1.3.1

8) Replace the O-ring on the sensor box where the old 90 degree pressure line fitting was located. Install the 4S-4857 tee fitting in the sensor box to a torque of 11 +/- 1 Nm (97 +/- 9 lb-in).

Image1.4.1

9) Where applicable, perform Service Letter REBE3391 at this time.
10) Install sensor box bracket and existing heat shield. Tighten all six bolts to a torque of 12 +/- 3 Nm (106 +/- 27 lb-in).
11) Install sensor box, new pressure lines (tube assemblies), thermocouples onto DPF, and cable straps.

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

Image1.5.1

12) 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.