PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REROUTING THE SHUNT LINE ON CERTAIN C13 AND C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN CHASSIS WITH A METAL SHUNT TANK Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REROUTING THE SHUNT LINE ON CERTAIN C13 AND C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN CHASSIS WITH A METAL SHUNT TANK

Usage:

REBE4391-00

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02Oct2008

U-507

A-420

TT-32

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REROUTING THE SHUNT LINE ON CERTAIN C13 AND C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN CHASSIS WITH A METAL SHUNT TANK
1350 1380		PS42801

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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 "PS42801" 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

31Oct2010

PROBLEM

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The shunt line connected next to the draw down port at the temperature regulator housing can cause reverse flow up the shunt line and back into the radiator, resulting in overcooling.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C13	LEE00530, 638, 669, 709-711, 713, 877-881, 900, 1023, 1025-1026, 1074, 1153-1154, 1159, 1162, 1166-1167, 1176, 1183-1185, 1187, 1190-1192, 1262, 1264, 1395, 1397, 1411, 1420-1421, 1425, 1434, 1444, 1455, 1462, 1477, 1490, 1506, 1511, 1527-1528, 1530, 1538, 1540, 1544, 1550, 1553-1555, 1557, 1566, 1569, 1577, 1579, 1591, 1709, 1802, 1805, 1851, 1853-1854, 1871, 1883, 1887, 1889, 1893, 1897, 1899, 1906, 1909, 1912, 1914, 1916, 1921, 2137, 2177, 2182, 2206, 2215, 2227, 2252, 2309, 2318, 2328-2329, 2350, 2408, 2416, 2420, 2427, 2445, 2511, 2521, 2538, 2542-2544, 2557, 2560, 2564, 2566, 2581, 2585, 2590-2591, 2601, 2605, 2610, 2612, 2620-2621, 2626, 2631, 2638, 2641, 2647, 2650, 2654, 2665, 2674, 2682, 2684-2685, 2691, 2721-2722, 2740-2741, 2778, 2781, 2790, 2909, 2918, 2921, 2937, 2965, 2967-2968, 2976, 2988, 2998, 3007, 3010, 3014, 3030, 3035, 3038, 3040-3041, 3043, 3047-3051, 3053, 3055, 3057-3059, 3064, 3070-3071, 3160, 3163, 3165, 3190, 3234, 3251, 3268, 3272, 3302, 3304, 3318, 3336, 3351, 3363, 3413, 3451, 3476, 3487, 3498, 3502, 3535, 3597, 4038, 4085, 4097, 4099, 4112, 4161-4162, 4188, 4308, 4447, 4700, 4766, 4789, 5545, 5887, 5907, 6544, 7011, 7017, 7023, 7071, 7075, 7097, 7215, 7236, 7326, 7330, 7343, 7347, 7353, 7364, 7377, 7380, 7384, 7416, 7426, 7429, 7445, 7447, 7459, 7468, 7472, 7495, 7498, 7500, 7511, 7515, 7530, 7535, 7539, 7544, 7549, 7564, 7646-7647, 7669, 7676, 7702, 7707-7708, 7714, 7717, 7727-7728, 7732, 7790-7792, 7794-7795, 7817, 7819, 7825, 7827, 7841, 7851, 7859, 7866, 7875, 7894, 7896, 7904-7905, 7915, 7919, 7927, 7930, 7937, 7939, 7955, 7974, 7980, 7997, 8016, 8024, 8035-8036, 8049, 8070, 8076, 8078, 8080, 8085, 8097, 8101, 8123, 8125-8126, 8128, 8132-8133, 8135, 8137, 8140, 8156, 8230, 8242, 8255, 8276, 8604, 8624, 8662, 8734, 8738, 8758, 8881, 8884-8886, 8888, 9100, 9231, 9238, 9248, 9252, 9329, 9335, 9341, 9345, 9351, 9354, 9357, 9362-9363, 9370, 9392, 9848, 9854, 9888, 10000, 10004, 10012, 10031, 10093, 10141, 10218, 10384-10385, 10618, 10769, 10930, 10940-10941, 10944, 10953, 10993-10994, 11050, 11057, 11072, 11146-11147, 11150, 11155-11156, 11158, 11171, 11187, 11192, 11203, 11216, 11224, 11230, 11240, 11249, 11254, 11267, 11269, 11280, 11286, 11293-11296, 11299-11300, 11303, 11310, 11313-11315, 11317-11318, 11320-11321, 11384, 11386, 11451, 11525, 11565, 11720, 11753, 11768, 11779, 11797, 11805, 11822, 11875, 11882, 11884-11885, 11989, 12131, 12138, 12147, 12149, 12235, 12245, 12298, 12314-12315, 12319, 12322, 12324, 12330, 12341, 12345, 12351, 12355-12356, 12359, 12368, 12377, 12389, 12419, 12479, 12505, 12511, 12514, 12517, 12520, 12539, 12552, 12562, 12564, 12579-12580, 12583, 12585, 12588-12589, 12596-12599, 12605-12606, 12620, 12623, 12628-12629, 12631, 12636, 12761, 12771, 12836, 12886, 12890, 12908-12909, 12926, 12940, 12942, 12953, 12956, 12973, 13006, 13012, 13014, 13018, 13022, 13024, 13029-13030, 13040, 13043, 13088, 13583, 13590, 13603, 13606, 13609, 13621, 13623, 13636, 13643, 13649, 13651-13652, 13655, 13667, 13670, 13867, 13873, 13884, 13889, 13914, 13918, 13924, 13928, 13948, 13955, 13964, 13970, 13975, 13979, 13997, 14006, 14011, 14016, 14024, 14038, 14108, 14150, 14595, 14601, 14603, 14631, 14636, 14646, 14650, 14658, 14664, 14673, 15344, 15353, 15361, 15380, 15393, 15445, 15674-15675, 15691, 15697, 15712, 15717-15718, 15744, 15746, 15862, 15922, 15931, 15936-15937, 15945, 15951, 15953, 15959, 15973, 15991, 15996, 16006, 16022, 16036, 16209, 16212-16213, 16217, 16223-16226, 16228, 16235, 16240, 16256, 16259, 16360, 16375, 16454, 16457, 16459, 16464, 16466, 16477, 16494, 16503, 16656, 16688, 16726, 16740, 16895, 17099, 17104, 17111, 17120, 17130, 17132, 17140, 17143-17145, 17153, 17171, 17197, 17263, 17266, 17270, 17272, 17280, 17296, 17303, 17306, 17309, 17314, 17365, 17430, 17478, 17671, 17705, 17710, 17807, 17809, 17811-17812, 17819, 17826, 17829-17830, 17846, 17861, 17863, 17865, 17902, 17919, 18020, 18053, 18065, 18297, 18313, 18388, 18400, 18419, 18428, 18432, 18438, 18465, 18468, 18627, 18645, 18652, 18656, 18819, 18905, 18914, 18918, 19593, 19599, 19612, 19647, 19657, 19664, 19872, 19878, 19943, 19947, 19963

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*******Group 2*******

C15

SDP00227, 532-533, 535, 546, 633-634, 638, 700, 704, 778, 780, 860, 863, 869, 1113-1114, 1117-1118, 1134-1136, 1144, 1153, 1160, 1167, 1254, 1258, 1264, 1268, 1270, 1273, 1275-1277, 1282, 1285, 1293, 1300, 1312, 1320-1321, 1327, 1477, 1516, 1522, 1529, 1539, 1559, 1569, 1571, 1574, 1590, 1625-1626, 1769, 1785, 1808, 1878, 1976, 1989, 2051, 2068, 2083, 2085, 2095, 2108, 2120, 2134, 2146, 2186, 2194, 2198, 2211, 2339, 2350, 2496, 2580, 2670, 2840, 2877, 2885, 2887, 2901, 2903, 2905, 2909, 2916-2917, 2928, 2931, 2933-2934, 2936-2937, 2940, 2942-2945, 2947, 2949-2951, 2957, 2965, 2973, 2976, 2978-2980, 2982, 2988-2990, 2992, 3181, 3199, 3215, 3221, 3224-3225, 3383, 3425, 3428, 3466, 3470, 3482, 3516, 3524, 3536, 3543, 3565-3566, 3578, 3589, 3596, 3613, 3616, 3621, 3628, 3634, 3640, 3647, 3802, 3824, 3856, 3869, 3878, 3891, 3904-3905, 3911, 3917, 3921, 4465, 4823, 4937, 4942, 4985, 5000, 5022, 5024, 5112, 5156, 5193, 5262, 5278, 5287, 5292, 5294-5295, 5305, 5318, 5381, 5383, 5405-5406, 5428, 5438, 5440-5441, 5470, 5473, 5478, 5488, 5515, 5517, 5520, 5529, 5578, 5585, 5726, 5805, 5819, 5824, 5832, 5837, 5878, 5886, 5890, 5911, 5924, 5929, 5942, 5953, 5964-5965, 5967, 6183, 6214, 6304, 6536, 6554-6555, 6557, 6610, 6792, 6833, 6836-6837, 6850, 6854-6856, 6860, 6868-6870, 6881, 6885-6886, 6889, 6892, 6895, 6900-6901, 6904, 6906, 6908, 6910, 6913, 6916-6917, 6924, 6927-6928, 6931, 6940, 6944, 6948, 6960, 7029, 7037, 7049, 7059, 7062, 7069, 7076, 7079, 7090, 7100, 7114, 7117, 7130, 7151-7152, 7239, 7261, 7320, 7326, 7379-7380, 7402, 7646, 7666, 7720, 7734, 7743, 7745, 7756, 7759, 7765-7766, 7769, 7771, 7773, 7777, 7781, 7784, 7788, 7792, 7795, 7800, 7806, 7808, 7812, 7824, 7832, 7838, 7845, 7849, 7919, 8133, 8145, 8172, 8185, 8191, 8209, 8213, 8215, 8226, 8248, 8250, 8262, 8267, 8273, 8292, 8297, 8299, 8307, 8343, 8350, 8359, 8371, 8376, 8385, 8389, 8408, 8419, 8440, 8470, 8489, 8529, 8538, 8551, 8580, 8620, 8625, 8648, 8652, 8673, 8683, 8688, 8691, 8701, 8709, 8711, 8718, 8727, 8729, 8737, 8757, 8769, 8781, 8789, 8811, 8835-8836, 8841, 8844-8845, 8847, 8852, 8857, 8865, 8870, 8874, 8925, 8930, 8934-8936, 8951-8952, 8957, 8959, 8978, 8983, 9001, 9007, 9014-9015, 9024-9026, 9032, 9040-9041, 9046, 9149, 9155, 9159, 9163-9164, 9166-9167, 9174, 9222, 9245, 9251, 9253, 9255-9256, 9263, 9278, 9287, 9289, 9298, 9303-9304, 9307, 9313, 9321, 9324, 9331, 9341, 9351, 9355, 9360-9361, 9369, 9378-9379, 9382, 9389-9390, 9400, 9410, 9416, 9462, 9465, 9468-9469, 9471-9472, 9474, 9476-9477, 9575, 9587, 9589-9590, 9598, 9616, 9627, 9642, 9650, 9659, 9706, 9724, 9726, 9737, 9745, 9754, 9769-9770, 9777, 9780, 9783, 9790-9791, 9805, 9816, 9828, 9841, 9860, 9863, 9865, 9877, 9880, 9884, 9887, 9902, 9914, 9921, 9927, 9958, 9970, 9982-9983, 9991, 9993, 10001, 10003, 10043, 10045-10047, 10061, 10068, 10078, 10083-10084, 10087-10088, 10091, 10112, 10116-10117, 10121-10122, 10124, 10135, 10207, 10237, 10271, 10273, 10275, 10308, 10312, 10322-10324, 10330, 10335, 10341, 10343, 10346-10348, 10351, 10353-10354, 10356-10362, 10364-10366, 10368, 10371-10372, 10374-10375, 10378, 10384, 10388, 10390, 10392-10393, 10395, 10399, 10406, 10412, 10418-10419, 10421, 10423, 10426, 10433, 10437, 10443, 10447-10448, 10450, 10452-10453, 10459, 10462, 10466, 10470, 10472, 10475-10476, 10478, 10482-10484, 10486-10487, 10492, 10494-10495, 10499-10501, 10503, 10505, 10507, 10522-10523, 10528-10530, 10532, 10537-10538, 10544-10546, 10548, 10560-10562, 10572, 10576, 10580, 10587, 10592, 10594, 10596-10601, 10604, 10608-10611, 10614, 10617-10618, 10621-10624, 10626, 10629-10631, 10633, 10643, 10645, 10647, 10652, 10656, 10663, 10676, 10685, 10694, 10700, 10704-10707, 10711, 10725, 10743, 10747, 10749, 10760, 10762, 10766, 10769, 10777, 10788, 10792-10793, 10821, 10837, 10840, 10847, 10850, 10852, 10854, 10858-10859, 10861, 10868, 10879, 10882, 10885-10889, 10894-10895, 10899, 10903-10904, 10907, 10910-10911, 10917-10918, 10921, 10925, 10930, 10945, 10952, 10955, 10971, 10984-10985, 10987, 10990, 10993, 10998, 11018, 11020, 11022, 11025-11026, 11028, 11031, 11037, 11046-11047, 11057, 11065, 11067, 11090-11091, 11094, 11098-11101, 11103, 11105-11108, 11110-11111, 11116, 11118-11119, 11121, 11123, 11143, 11161, 11203, 11217, 11231, 11234, 11245, 11634, 11644-11645, 11650, 11658, 11665-11666, 11672, 11687-11688, 11694-11695, 11697, 11700, 11731, 11760-11762, 11764, 11771, 11774, 11785-11786, 11805, 11809-11810, 11816, 11819, 11839, 11900, 11902, 11904, 11909, 11912, 11918, 11923, 11925, 11927, 11930, 11990, 11992, 12036, 12046, 12824, 12852, 12855, 12868, 12895-12896, 12898-12899, 12901, 12931, 12936, 12939-12940, 12944-12945, 12954, 12971, 12975, 12986, 12998, 13012-13013, 13016, 13040, 13056, 13060, 13064, 13100, 13106, 13144, 13325, 13373, 13379, 13384, 13395, 13404, 13445, 13453, 13467, 13472, 13486, 13501, 13505, 13510, 13524, 13529, 13559, 13561, 13565, 13588, 13595, 13632, 13644, 13683, 13689-13690, 13697, 13707, 13717, 13723, 13725-13726, 13734, 13736, 13738, 13743-13744, 13746, 13748, 13752, 13771, 13775, 13785-13787, 13812, 13817, 13819, 13821, 13826-13827, 13832-13833, 13865, 13883, 13905, 13918-13919, 13936, 13942, 13954, 13962, 13965, 13977, 13981, 13986, 13989, 14001, 14047, 14059, 14063, 14079, 14087, 14120, 14141, 14148, 14157, 14217, 14219, 14224, 14255, 14293, 14302, 14312, 14319-14320, 14327, 14355, 14381, 14399, 14403-14404, 14409, 14427, 14430-14431, 14456, 14487, 14501, 14536, 14840, 14870, 14874, 14912, 14923, 14960, 14975-14976, 15008, 15080, 15090, 15113, 15140, 15147, 15187, 15194, 15261, 15291, 15296, 15322, 15342, 15398, 15401, 15410, 15418, 15424, 15432, 15442, 15444, 15450, 15464, 15466, 15494, 15520, 15590, 15617, 15622, 15642, 15693, 15698, 15717, 15724-15725, 15728, 15742, 15745-15746, 15792, 15806, 15817, 15863, 15877, 15881, 15891, 15898, 15902, 15983, 16131, 16154-16155, 16158, 16161, 16167, 16169-16170, 16181, 16186, 16188, 16191, 16193, 16197, 16249, 16307, 16384, 16406, 16446-16447, 16454, 16456, 16458, 16460-16461, 16468-16469, 16482, 16485, 16487, 16489, 16501, 16516, 16539, 16557, 16595, 16605, 16607, 16613, 16624, 16664, 16690, 16694, 16701, 16738, 16750, 16757, 16788-16790, 16795, 16798-16800, 16802, 16806, 16808, 16811-16816, 16819, 16821, 16823, 16827, 16830-16836, 16838, 16845-16846, 16849, 16851, 16853-16855, 16896-16897, 16904, 16945, 16949, 17002, 17005, 17009, 17014, 17048, 17059, 17062-17063, 17066-17068, 17079, 17098, 17116-17117, 17134, 17141, 17148, 17155, 17167, 17202, 17241, 17318, 17388, 17452, 17516, 17564, 17582, 17594, 17626, 17661, 17702, 17739, 17745, 17756, 17836-17838, 17848, 17878, 17904, 17965, 17992, 17998, 18013, 18029, 18032, 18050, 18069, 18079, 18090, 18099, 18102, 18109-18110, 18119, 18122-18123, 18126, 18134-18135, 18137, 18149, 18153, 18156-18157, 18159, 18188, 18222, 18263, 18271, 18285, 18291, 18296, 18307, 18312, 18323, 18329, 18334, 18339, 18362, 18384, 18387, 18407, 18411, 18436, 18457, 18462, 18475-18476, 18485, 18487, 18489, 18493, 18500, 18512, 18515, 18524, 18528, 18532, 18535-18536, 18539, 18541, 18549, 18551, 18586, 18588, 18593, 18596, 18602, 18651, 18678, 18696-18697, 18704, 18718, 18722, 18844, 18862, 18869, 18872, 18890, 18899-18900, 18908, 18914, 18953, 18960, 18982, 18998, 19003, 19007, 19019, 19026, 19045, 19057, 19068, 19125, 19138, 19142, 19145, 19157, 19159, 19174, 19190, 19220, 19226, 19256, 19275, 19279, 19285, 19288, 19297, 19312, 19316, 19319, 19334, 19336, 19368, 19384, 19387, 19397, 19402, 19410, 19474, 19478, 19483-19484, 19486, 19498, 19509, 19513, 19517, 19522, 19524, 19526, 19528, 19534, 19539, 19541, 19554, 19560, 19566, 19571-19572, 19574, 19580, 19583, 19587-19588, 19593-19594, 19598, 19645-19646, 19648, 19650-19651, 19653-19660, 19663-19664, 19666, 19673-19674, 19676, 19679, 19746, 19780, 19793-19794, 19822, 19835-19836, 19839, 19843-19844, 19846, 19848, 19850, 19857-19859, 19861, 19866, 19870, 19873, 19878-19879, 19887, 19890, 19899, 19903, 19905, 19908-19909, 19913, 19915, 19920-19921, 19924, 19928-19930, 19937-19939, 19941, 19943, 19947-19948, 19952-19953, 19956-19957, 19961, 19964-19966, 19980, 19986, 19993, 20021, 20023, 20028, 20034-20035, 20037, 20040, 20042, 20047-20048, 20053, 20056, 20058, 20063-20064, 20069, 20071-20073, 20078, 20080-20085, 20088-20091, 20093, 20096-20099, 20102-20103, 20107-20110, 20113-20114, 20117-20118, 20120-20121, 20124, 20126-20127, 20129, 20131-20133, 20136-20137, 20141, 20148, 20151-20154, 20157, 20161-20162, 20164-20165, 20171-20175, 20184, 20187, 20191, 20195-20196, 20199, 20205, 20207-20208, 20212, 20221, 20226, 20228, 20243, 20247, 20249-20252, 20263, 20281, 20296, 20310, 20333, 20345, 20380, 20409, 20435, 20506, 20508, 20511, 20546, 20558, 20744, 20757, 20769, 20773, 20775, 20780, 20783, 20785, 20787-20790, 20793, 20799, 20802-20803, 20805, 20807, 20810-20812, 20816-20817, 20819, 20821-20822, 20828-20830, 20832, 20834-20837, 20842, 20849, 20853, 20866, 20877

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	D20066314	Fitting (OEM part)
1	F501050	Bulk 1 inch hose, 7 ft (OEM pn F50-1050-2100)
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	D20066314	Fitting (OEM part)
1	F501050	Bulk 1inch hose, 5.5 ft (OEM pn F50-1050-1680)
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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Inspect the routing of the shunt line. If the shunt line is not connected at the water pump inlet elbow, reroute the shunt line. Refer to the attached rework procedure for a typical example of the rerouting of the shunt line.

If the shunt line is connected to the pump inlet elbow, no further action is needed.

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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*****
0-500000 miles, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 1
Inspect shunt line routing______0.5 hour______1361-011-S $120 can be claimed to order the parts from the truck OEM.

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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*****
0-500000 miles, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 2
Inspect shunt line routing______0.5 hour______1361-011-S $120 can be claimed to order the parts from the truck OEM.

PARTS DISPOSITION

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

Rework Procedure

Group Number 1

1. Remove the current shunt line and lower fitting (Image 1.1.1)

2. Remove the plug from the water pump inlet elbow and replace with the fitting removed in Step 1.

3. Route a new shunt line in a continuous downward slope from the tank to the fitting installed in the water pump inlet elbow. (Trim hose to per installation for proper fit)

4. Install the D20066314 plug into the hole left by removing the fitting in Step 1.

Image1.1.1

Group Number 2

1. Remove the current shunt line and lower fitting (Image 2.1.1).

2. Remove the plug from the water pump inlet elbow and replace with the fitting removed in Step 1.

3. Route a new shunt line in a continuous downward slope from the tank to the fitting installed in the water pump inlet elbow. (Image 2.1.2) (Trim hose per installation for proper fit)

4. Install the D20066314 plug into the hole left by removing the fitting in Step 1.