PRODUCT SUPPORT PROGRAM FOR REPLACING THE DIESEL PARTICULATE FILTER (DPF) ON C9 ENGINES INSTALLED IN MASS TRANSIT BUSES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE DIESEL PARTICULATE FILTER (DPF) ON C9 ENGINES INSTALLED IN MASS TRANSIT BUSES

Usage:

REBE4638-02

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09Feb2009

(Revised 26Mar2009)

B170

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE DIESEL PARTICULATE FILTER (DPF) ON C9 ENGINES INSTALLED IN MASS TRANSIT BUSES
108F		PS42877

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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 "PS42877" 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 09Feb2009 (Revised 10Feb2009) Service Letter. Changes have been made to Parts Needed, Service Claims Allowances, and Rework Procedure.

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TERMINATION DATE

28Feb2011

PROBLEM

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The existing Diesel Particulate Filters (DPF) can allow excessive soot to exit in the exhaust on certain C9 engines installed in mass transit buses.

AFFECTED PRODUCT

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Model	Identification Number
C9	MTB00105, 109-111, 113-172, 174-177, 179-190, 197-199, 2003

PARTS NEEDED

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Qty	Part Number	Description
4	1K6872	LOCKNUT
8	3B4504	LOCKWASHER-1/4
2	3B4507	LOCKWASHER-7/16
2	4B1232	SCREW-MACHINE
4	4B4274	WASHER
2	4M5282	BOLT
8	6D4246	CLIP
30	6K0806	STRAP-CABLE
2	6V5729	LOCKNUT
4	6V8185	NUT-FULL
4	7X0325	BOLT
2	8T4205	WASHER-HARD
1	7460K41	3 Amp Fuse
2	031049	Lock Nut
2	90064A581	Self Tapping Screws
4	1264877	TUBE AS
1	2167990	INSTALLATION AS
1	2716537	MONITOR GP- EXH
1	2820031	DISPLAY-REMOTE
1	3358406	FILTER GP-DPF
1	BRACKET	Dealer Fabricated CCRT Bracket
4	GROMMET	Grommet (97-2246-00002)
1	R.DBRACKET	Dealer Fabricated Remote Display Bracket
2	X007785	Exhaust Clamp (OEM Part)
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 current DPF with new 335-8406 (CCRT).

Refer to the attached Rework Procedure.

NOTE: Some dealer fabricated parts are required to perform the Rework. Make sure fabricated parts are available.

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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%
0-200000 miles, 0-72 mo	50.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 10.2-hour job
- 6.7 Hours for Labor (Removal & Installation of DPF) - 3.5 Hours for fabrication of brackets (DPF Bracket & Remote display Bracket). - $38 per repair will be allowed as material cost for bracket fabrication. Reasonable travel time and mileage will be allowed when applicable.

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. Return 50% DPF parts to customer.

Rework Procedure

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Procedure for Replacing the Diesel Particulate Filter (DPF)

Introduction
This Rework Procedure provides the proper procedure for replacing the Diesel Particulate Filter on engines that are installed in buses built by Neoplan. Do not perform any this Rework Procedure until you read and fully understand this information.

Procedure to Properly Replace the Diesel Particulate Filter

Image1.1.1

(1) Inlet pipe (2) Pressure tube

Disassembly of the Diesel Particulate Filter

1. Remove the inlet pipe. Loosen and remove the pressure tube from the inlet. Retain the inlet pipe and fasteners for reuse. Refer to Image 1.1.1.

Image1.2.1

(1) Mounting brackets (2) Outlet pipe

2. Use a transmission jack with DPF properly secured to support the filter. Loosen mounting brackets shown in Image 1.2.1 and lower the DPF. Remove the mounting brackets from the chassis.

3. Remove the outlet pipe (2) retain for reuse. Image 1.2.1

4. Remove the DPF Monitor Module shown in Image 1.3.1.

5. Fabricate CCRT bracket shown in Image 1.3.2 to Image 1.3.5. Image 1.3.2 is the basic representation of the bracket and Images 1.3.3 to 1.3.5 are pictures of the bracket.

The CCRT bracket is: 13" in diameter. 2.0" wide. Bolt holes are 1/2" diameter and slotted 3/4". The material for the bracket is 3/16" mild steel flat stock, Tensile strength 42,000 to 50,000 lbs.

Image1.3.1

Image1.3.2

Image1.3.3

Image1.3.4

Image1.3.5

6. Fabricate Display bracket shown in Image 1.4.1 to 1.4.4. The material used for the bracket is 3/16" mild steel flat stock. Tensile strength 42,000 to 50,000 lbs.

Image1.4.1

Image1.4.2

Image1.4.3

Image1.4.4

Image1.4.5

Assembly of the Replacement CCRT:

1. Install the 335-8406 CCRT.
- Remove all CCRT kit parts from the shipping container.
- Assemble the dealer fabricated CCRT brackets onto bus chassis. Replace the bolts and nuts previously removed from the DPF brackets with 7X0325 (Bolts) & 1K6872 (Nuts).
- Do not tighten completely at this time.
- Orient the CCRT so that the outlet socket is at the lowest position. Install the tailpipe into the outlet socket with the discharge down. Tap the tailpipe into the outlet socket until the inside edge is flush with the inside of the socket. Verify the tailpipe is properly seated by reaching inside of the tail pipe and feeling the location of the edges. Refer to Image 1.4.5
- Install the clamp and tighten to a torque of approximately 50 lb ft.

Image1.5.1

2. Use 4 new grommets (MCI part number 97-2246-00002 (Dealer Order)) per bus. Grommets are to be installed between the clamp and chassis frame at same location as originals.

3. Clean existing exhaust inlet pipe with wire brush for reuse. Install new Exhaust clamps (Dealer Order).

4. Clean existing exhaust Outlet pipe with wire brush for reuse. Install new Exhaust clamps (Dealer Order).

5. Use a floor jack or transmission jack with CCRT properly secured to lift into place. Place a pipe clamp loosely over the inlet socket. Use the jack to raise the CCRT assembly into position. Insert exhaust pipe elbow into inlet socket. Tighten the clamp bolt to a torque of approximately 50 lb ft. Refer image 1.5.1.

Image1.6.1

6. Provide adequate clearance to Pro Heat exhaust pipe. Mounting brackets will have 1/2 inch slotted bolt holes. Orient to provide needed clearance. Refer image 1.6.1.

Image1.7.1

7. Install Thermocouple.
- Apply a thin coat of anti-seize to the threads of the Male Run Tee and thread it into the boss on the CCRT inlet. Image 1.7.1 shows a completed installation.
- All the parts used from Step 7 to Step 10 are included in the 219-7990 Installation Kit.

Image1.8.1

8. Insert the reducer fitting into the Tee fitting in line with the boss (Image 1.8.1). Tighten the lock nut (also use the Lock Washer) on the Tee until it is finger tight and then tighten it 1 1/4 turns with a 9/16" wrench.

Image1.9.1

9. Insert the thermocouple into the reducer as far as it will go, then pull it back 1/4 inch (Image 1.9.1). Tighten the lock nut finger tight and then tighten 1 1/4 turns with a 7/16" wrench. If necessary, the thermocouple may be bent ONCE to avoid any interference. Do not bend the thermocouple past 90 degrees.

NOTE. JM instructions instruct to insert probe and withdraw one inch. For this installation, insert probe and withdraw 1/4 inch to allow accurate temperature measurement of the exhaust.

Image1.10.1

10. Insert the copper tubing into the fitting on the Tee that is at a 90 degree angle to the boss (Image 1.10.1). Tighten the fitting on the Tee until it is finger tight. Then tighten it 1 1/4 turns with a 9/16" wrench.

Image1.11.1

Image1.11.2

11. Route the cable and copper tube and the secure cable with 6K0806 Cable Straps as shown. It is important to use these cable straps so the tube and cable are oriented in a way that they do not rub against the frame.

Install P brackets every two to three feet as needed. Refer in Image 1.11.2.

12. Install 271-6537 CCRT Diagnostic Module using Bolts (4M5282), Washers (8T4205), nut (6V8185) and Lock Washer (3B4504). Use carbide tip drill bit for drilling in stainless steel.

Image1.13.1

13. Install 282-0031 Remote Display monitor lights along with dealer fabricated Remote Display Bracket. Use self tapping screws (90064A581), Splice (1364877), Washer (4B4274), Locknut (031049) and screw (4B1232).

Image1.14.1

14. Connect power using 3A Fuse.

15. Install existing Pin insulator on the weatherpack plug that connects to the OEM harness at the firewall that provides power to the CRT module.
16. Download the JM program to CRTdm module. Reference software # 271-6537-00.cpf
17. Complete the JM form (FDS-S-0019) provided with installation kit.