PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXHAUST COMBUSTION GROUPS INCLUDING THE EXTENSION PIPE ON CERTAIN C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN FREIGHTLINER CHASSIS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXHAUST COMBUSTION GROUPS INCLUDING THE EXTENSION PIPE ON CERTAIN C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN FREIGHTLINER CHASSIS

Usage:

REBE4640-02

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09Jan2009

(Revised 20Mar2009)

U-11

A-10

TT-2

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXHAUST COMBUSTION GROUPS INCLUDING THE EXTENSION PIPE ON CERTAIN C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN FREIGHTLINER CHASSIS
108B 1061		PI10733

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10733" 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 "PI10733" 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:	This Revised Service Letter replaces the 09Jan2009 (Revised 05Feb2009) Service Letter. Changes have been made to Owner Notification.

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PROBLEM

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This Product Improvement Program is a Safety Recall in accordance with the US National Traffic and Motor Vehicle Safety Act and the Canadian Motor Vehicle Safety Act. The extension pipes attached to the Aftertreatment Regeneration Device (ARD) may develop a crack or hole and heat and flame may escape during a regeneration of the
Diesel Particulate Filter, which may result in a fire hazard. It is a violation of US Federal law for a dealer to deliver a new motor vehicle or new or used engine covered by this Safety PIP until the PIP has been completed.

AFFECTED PRODUCT

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Model	Identification Number
C15	SDP04270, 4279, 4449, 4461, 4463, 4796, 4808, 4850, 4856, 5549, 5569, 5576, 5602, 5675, 5692, 5718, 5753, 5756, 5763, 6438, 6486, 6498, 6529, 6535, 6581, 6597, 7962, 8819, 9333, 9347, 9470, 9489, 10048, 10131, 10180, 10227, 10539, 10542, 10563, 10651, 10653, 10666, 10678-10679, 10709, 10720, 10731, 13304, 13385

PARTS NEEDED

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Qty	Part Number	Description
2	2967780	GASKET
1	3254598	BODY-MACHINED
1	3342911	EXTENSION AS
1	3342913	SHIELD-HEAT
1	3342914	SHIELD-HEAT
2	BOLT	Freightliner part # 23-12094-200
1	BRACKET	Freightliner part # 04-26993-000
1	CLAMP	Freightliner part # A04-09364-000
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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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 4.3-hour job
Dealer to perform most economical repair. Description___________________SMCS Code______Hours Wash__________________________108B-074_______0.3 Perform rework procedure _____108B-010_______3.2 ECM Flash_____________________1901-591_______0.5 Test after repair_____________108B-030_______0.3 $240 can be claimed to order the parts from the truck OEM. 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

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXHAUST COMBUSTION GROUPS INCLUDING THE EXTENSION PIPE ON CERTAIN C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN FREIGHTLINER CHASSIS

MODELS INVOLVED - C15 On-Highway Truck Engines

Dear Caterpillar Product Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. This notice is also in accordance with the requirements of the Canadian Motor Vehicle Safety Act. Caterpillar has decided that a defect which relates to motor vehicle safety exists in certain Caterpillar C15 truck engines installed in certain 2008 Freightliner Century ST and Columbia trucks.

The extension pipes attached to the Aftertreatment Regeneration Device (ARD) body may develop a crack or hole and heat and flame may escape during a regeneration of the Diesel Particulate Filter,
which may result in a fire hazard. The ARD body will be replaced and software updated.

Caterpillar had previously sent you a notification letter strongly recommending that you not operate your vehicle and to contact your Caterpillar dealer immediately to have the extension pipe inspected. This letter is to notify you that the remedy is available to be applied. Contact your Caterpillar dealer immediately to have the extension pipe replaced for the engine serial numbers listed below. You will not be charged for the service performed.

If you are a lessor of these vehicles, you must forward this letter to your lessee within ten days.

If you have had your vehicle repaired for this condition prior to receipt of this notice and incurred any costs, you may be eligible for reimbursement. Please contact Caterpillar at this toll free number (800) 447-4986.

If you no longer own the truck with this engine, please contact Caterpillar at this toll free number (800) 447-4986.

Contact your local Caterpillar dealer immediately to schedule this service.

If the dealer is unable to have the inspection and repair made, please contact:

Caterpillar Inc.
PO Box 610
Mossville, IL 61552-610
Attn: Engine Products Division
Truck Engine Call Center
Telephone: (800) 447-4986

If you are unable to have the repair made within 60 days or without charge, you may submit a complaint to:

In the U.S.
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Avenue, S.E.
Washington, D.C. 20590
Telephone: 1-888-327-4236 (TTY:1-800-424-9153)or go to http://www.safercar.gov

In Canada
Transport Canada
Road Safety and Motor Vehicle Regulation
Ottawa, Ontario KIA 0N5
Telephone: (613) 993-9851

Please refer the dealer to their Service Letter dated 09Jan2009 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 09Jan2009 Service Letter

Rework Procedure

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1. Perform an ECM warranty download using Cat ET.

2. Remove combustion head group (ARD) by following steps 1-3 in media RENR9706 "Combustion Head Group (ARD) ? Removal Procedure".

3. Remove combustion body group (ARD) by referencing RENR9706 "Combustion Body Group (ARD) - Removal Procedure".

4. Remove 304-1024 and 304-1025 Heat Shields from the old ARD Body and install on the new 325-4598 ARD Body. Reuse the hardware from original combustion body. Tighten bolts to a torque of 12 +/- 1 Nm. Refer to Images 1.1.1 and 1.1.2.

Image1.1.1

Image1.1.2

5. Remove the old ARD extension pipe assembly. Remove 3 band clamps for reuse.

6. Install combustion air tube assembly into the new 325-4598 combustion body. Refer to image 1.2.1.

7. Apply anti-seize compound to the threads of 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 N.m (12.5 +/- 1.5 lb ft). Refer to image 1.2.1.

Image1.2.1

8. Install the combustion body group by referencing media RENR9706 "Combustion Body Group (ARD) ? Installation Procedure".

9. Install combustion head group (ARD) by following steps 1-3 in media RENR9706 "Combustion Head Group (ARD) ? Installation Procedure".

10. Install 334-2913 and 334-2914 Heat Shields on the 334-2911 Extension Pipe with the band clamps that were removed from the original extension assembly. Tighten band clamps to a torque of 4 Nm +/- 1 Nm.

11. Assemble the flared end of extension pipe assembly to the combustion group body with V-band Clamp. Do not tighten clamp at this time.

12. Align extension pipe with chassis exhaust pipe. Do not tighten OEM supplied v-band clamp at this time.

13. Inspect for interferences with chassis or other components and align piping as necessary.

14. Tighten the V-band Clamp that connects the extension pipe to the combustion body to a torque of 12 +/- 1 Nm.

15. Tighten the OEM supplied v-band clamp that connects the extension pipe to the chassis exhaust according to OEM specifications.

16. Install the bracket assembly (obtained from Freightliner Dealer) to the OEM transmission mounting position as shown in image 1.3.1 and 1.3.2 with two bolts (obtained from Freightliner Dealer) and washers. Install the washers between the bracket and the transmission. Install lock washers under the bolt head (like OEM practice) for the remaining transmission mounting bolts. Refer to Images 1.3.1 and 1.3.2

Image1.3.1

Image1.3.2

17. Hand tighten the 2 bolts from the previous step.

18. Inspect for interferences with chassis and other components then align the bracket and extension pipe as necessary.

19. Tighten the 2 bolts on the OEM transmission to 70 +/- 15 N.m.

20. Perform ARD ignition test in CAT ET.

20. Perform an after repair ECM warranty report.