PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AFTERTREATMENT REGENERATION DEVICE (ARD)COMBUSTION BODY ON C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN CERTAIN INTERNATIONAL CHASSIS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AFTERTREATMENT REGENERATION DEVICE (ARD)COMBUSTION BODY ON C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN CERTAIN INTERNATIONAL CHASSIS

Usage:

REBE4585-00

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25Mar2009

U-121

A-107

TT-15

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AFTERTREATMENT REGENERATION DEVICE (ARD)COMBUSTION BODY ON C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN CERTAIN INTERNATIONAL CHASSIS
108B 1061		PI31649

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31649" 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 "PI31649" 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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NOTE:

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COMPLETION DATE	TERMINATION DATE
30Sep2009	31Mar2010

PROBLEM

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The existing Combustion Body on C15 On-highway truck engines installed in certain International chassis may be subjected to temperatures that are high enough to cause it to degrade prematurely.

AFFECTED PRODUCT

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Model

Identification Number

C15

SDP00414, 421, 879-882, 1100, 1193, 1271, 1290, 1814, 2097, 2101, 2136, 4519, 4531, 4539, 4784, 4788-4789, 4799, 4803, 4810, 4816, 5444, 5493, 5526-5527, 5730, 5743, 5788, 5858, 5988, 6348, 6356, 6358, 6414, 7274, 7347, 7349, 7639, 7945, 8279, 8305, 8367, 8494, 8745, 8770, 8814, 9006, 9029, 9314, 9326-9327, 9422, 9427, 9459-9460, 9499, 9529, 9610, 9624, 9637, 9643, 9655, 9951, 9975, 10350, 10404, 11781, 11970, 11985, 12459, 12574, 12635, 12652, 12709, 13791, 13858, 14482, 14564, 15036, 15160, 15204, 15239, 15688, 15722, 15820, 15885, 15935, 16074, 16083, 16256, 16755, 16921, 17093, 17126, 17139, 17191, 17818, 18468, 18474, 18554, 18689, 19046, 19507, 19515, 20150, 20319, 20337, 20339, 20492, 20623, 20666, 20951, 21256, 21310, 21333, 21346, 21399, 21452, 21501, 21599, 21690, 22285, 22390, 22419, 22430, 22445, 22481, 22487-22490, 22492, 22502, 22508, 22520, 22543-22545, 22624, 22633-22636, 22638, 22650-22651

PARTS NEEDED

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Qty	Part Number	Description
1	2886037	TUBE AS-AIR
1	2893107	GASKET
2	2967780	GASKET
1	3262868	BODY-MACHINED
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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The Combustion Body attached to the Aftertreatment Regeneration Head needs to be replaced.

Refer to the attached Rework Procedure.

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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%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 3.8-hour job
Dealer to perform most economical repair. Description___________________SMCS Code______Hours Wash__________________________108B-074_______0.3 Perform rework procedure______108B-010_______3.2 Test After Repair_____________108B-030_______0.3 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.

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 AFTERTREATMENT REGENERATION DEVICE (ARD)COMBUSTION BODY ON C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN CERTAIN INTERNATIONAL CHASSIS

MODELS INVOLVED - C15 On-Highway Truck Engines

Dear Caterpillar Product Owner:

Caterpillar has determined that the Combustion Body that is attached to the Aftertreatment Regeneration Device (ARD) needs to be replaced on C15 On-Highway truck engines listed below that are installed in certain International chassis. The existing Combustion Body may be subjected to temperatures that are high enough to cause it to degrade prematurely. 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 25Mar2009 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 25Mar2009 Service Letter

Rework Procedure

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Removal Procedure

1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".

2. Disconnect tube assembly (1) from the ARD head. Loosen clamp assembly (6) and remove tube assembly (1). Do not reuse the tube assembly and gasket. A new tube assembly and gasket will be installed. Refer to image1.1.1. and image1.1.2.

Image1.1.1

Image1.1.2

3. Disconnect flame detection temperature sensor (3). Refer to Image1.1.1.

4. Remove bolt (5) and clamp (6). Disconnect cable assembly (7) and (8). Remove bolt (9) and disconnect the cable assembly. Refer to Image1.2.1.

Image1.2.1

5. Disconnect hose assemblies (10). Refer to Image1.3.1.

Image1.3.1

6. Disconnect flame detection temperature sensor located near the bottom of the combustion body.

7. Remove the combustion body support assembly.

8. Remove nuts (12) and spacers (13), save for reuse. Refer to Image1.4.1.

Image1.4.1

9. Remove combustion head (14) and gasket (15). Remove flanged tube (16) and gasket (17). Remove tube (18). Remove the five studs (19). The flanged tube, combustion head, tube (18) and five studs (19) will be reinstalled on the new combustion body. Refer to Image 1.4.1.

10. Disconnect turbocharger outlet temperature sensor (17). Loosen clamp assembly (18) and remove combustion body group (16). Refer to Image 1.5.1.

Image1.5.1

Installation Procedure

1. Apply anti-seize compound to the threads of the original studs (19). Install studs (19) with the end that is marked "X" in the Up position. Tighten studs (19) to a torque of 17 +/- 2 Nm (12.5 +/- 1.5 lb ft). Refer to Image1.6.1.

2. Install original tube (18). Install new gasket (17) and install original flanged tube (16). Install new gasket (15) and install original combustion head (14). Refer to Image 1.6.1.

3. Apply anti-seize compound onto the threads of the studs (19) and nuts (12). Install spacers (13) and nuts (12). Tighten nuts (12) in a crisscross pattern to a torque of 23 +/- 3 Nm (17 +/- 2 lb ft). Tighten nuts (12) again in a crisscross pattern to a torque of 28 +/- 7 Nm (21 +/- 5 lb ft). Tighten nuts (12) again in a crisscross pattern to a torque of 28 +/- 7 Nm (21 +/- 5 lb ft). Refer to Image 1.6.1.

Image1.6.1

4. Apply anti-seize compound to the threads of clamp assembly (18). Position combustion body group (16) and install assembly (18). Tighten clamp assembly (18) to a torque of 11 +/- 2 Nm (98 +/- 18 lb in). Refer to Image 1.7.1.

5. Apply anti-seize compound on to the threads of turbocharger outlet temperature sensor (17). Install turbocharger outlet temperature sensor (17). Tighten turbocharger outlet temperature sensor (17) to a torque of 45 +/- 5 Nm (33 +/- 4 lb ft). Refer to Image 1.7.1.

Image1.7.1

6. Apply anti-seize compound to the threads of flame detection temperature sensor located near the bottom of the combustion body. Tighten flame detection temperature sensor to a torque of 45 +/- 5 Nm (33 +/- 4lb ft).

7. Connect hose assemblies (10). Refer to Image 1.8.1.

Image1.8.1

8. Position the cable assembly and install bolt (9). Connect cable assembly (8). Refer to Image 1.9.1.

Image1.9.1

9. Ensure that cable assembly (7) is fully seated prior to installing clamp (6) .

NOTE: Ensure that the ears of clamp (6) are facing upward. Install bolt (5). Torque bolt (5) to a torque of 3 +/- .5 Nm (27 +/- 5 lb in). Refer to Image 1.10.1.

NOTE: Ensure that the cable straps are installed at point (X) in order to keep the cable assemblies away from the combustion head. Refer to Image 1.10.2.

Image1.10.1

Image1.10.2

Image1.10.3

10. Position new tube assembly (1) and the new gasket. Install bolts (2) and tighten clamp assembly (6). Refer to Images 1.10.2 and 1.10.3.

11. Apply anti-seize compound to the threads of flame detection temperature sensor (3) and install the sensor. Refer to Image 1.10.2.

12. Fill the cooling system with coolant. Refer to Operation and Maintenance, "Refill Capacities" for the cooling system capacity.

13. Perform the ARD ignition test. Refer to Troubleshooting Manual, "ARD Ignition - Test".