PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AFTERTREATMENT REGENERATION DEVICE (ARD) COMBUSTION BODY AND EXTENSION PIPE ON CERTAIN C13 ON-HIGHWAY TRUCK ENGINES INSTALLED IN VAN HOOL CHASSIS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AFTERTREATMENT REGENERATION DEVICE (ARD) COMBUSTION BODY AND EXTENSION PIPE ON CERTAIN C13 ON-HIGHWAY TRUCK ENGINES INSTALLED IN VAN HOOL CHASSIS

Usage:

REBE5072-00

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30Apr2009

U-167

O-150

TT-21

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AFTERTREATMENT REGENERATION DEVICE (ARD) COMBUSTION BODY AND EXTENSION PIPE ON CERTAIN C13 ON-HIGHWAY TRUCK ENGINES INSTALLED IN VAN HOOL CHASSIS
108B 1061 108M		PI10755

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10755" 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 "PI10755" 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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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 pipe 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. This PIP identifies the final remedy repair and notifies the customer that the final remedy is available.

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

C13

LEE00705, 2232, 5373, 5376, 5389, 5397-5399, 5401, 5409-5410, 5413, 5421, 5423, 5428, 5432, 5436-5437, 5442, 5444, 5446, 5452, 5456, 5459-5461, 5468, 5470, 6083, 8505, 8831, 8842, 8853, 8864, 9418, 11628, 14302, 14505, 14570, 14604, 14633, 14728, 14741, 14783, 14785, 14909, 14913, 14969, 14994, 15072, 15094, 15115, 15133, 15221, 15231, 15262, 15330, 15365, 15379, 15453, 15481, 15560, 15565, 15597, 15659, 15703, 15745, 15789, 15835, 15879, 15921, 15964, 16002, 16029, 16058, 16129, 16853, 16896, 16942, 16979, 17032, 17074, 17159, 17165, 17670, 17697, 17747, 17762, 17808, 17835, 17881, 17884, 17960, 18010, 18077, 18093, 18127, 18142, 18186, 18198, 18261, 18267, 21943

PARTS NEEDED

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Qty	Part Number	Description
2	5P0599	CLAMP-BAND
1	8E9571	WASHER-HARD
2	8T8442	BOLT-SOCKET HEAD
1	2893107	GASKET
1	2893926	HOSE AS-F MAIN
1	2893927	HOSE AS-F PILOT
1	2893928	HOSE AS-COOLANT
1	2893929	HOSE AS-COOLANT
1	2893930	TUBE AS-AIR
2	2967780	GASKET
1	3008688	CLAMP-V-BAND
1	3009558	LOOM-HOSE
1	3079892	CLAMP-V-BAND
1	3253698	BODY-MACHINED
1	3282728	SHIELD - HEAT
1	3284158	SUPPORT AS
1	3401129	EXTENSION AS-EXH
1	3401135	SHIELD-HEAT
1	3401136	SHIELD-HEAT
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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Replace the Aftertreatment Regeneration Device (ARD) combustion body and extension pipe assembly on the affected product.

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 16.0-hour job

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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 - RECALL - REPLACEMENT OF THE AFTERTREATMENT REGENERATION DEVICE COMBUSTION BODY AND EXTENSION PIPE

MODELS INVOLVED - C13 On-Highway Truck Engines Installed in Van Hool Chassis

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 2008 model year trucks equipped with certain Caterpillar C13 truck engines.

The extension pipe 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. This is to notify you that the final remedy is available. This remedy will replace the ARD body and extension tube. 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. The dealer will advise you of the time required to complete 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 inspection and 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
Caterpillar Inc.

Please refer the dealer to their Service Letter dated 30Apr2009 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 30Apr2009 Service Letter

Rework Procedure

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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 combustion head. Loosen clamp assembly (6) and remove tube assembly (1). The tube assembly and gasket will be replaced with a new tube and gasket. Refer to Image 1.1.1 and Image 1.1.2.

Image1.1.1

Image1.1.2

3. Disconnect flame detection temperature sensor (3) from the combustion head. Refer to Image 1.1.1.

4. Remove bolt (5) and clamp (6). Disconnect cable assembly (7) and (8). Remove bolt (9) and disconnect the cable assembly. Disconnect hose assemblies (10) from the combustion head and the fuel manifold. The hoses will be replaced with new hoses. Refer to Image 1.2.1.

Image1.2.1

5. Remove five nuts (6) and four spacers (7). Remove combustion head (5). Remove gasket (4) and flanged tube (3). Remove gasket (2) and remove studs (8). Refer to Image 1.3.1.

Image1.3.1

6. Remove flame detection temperature sensor (10) from the backside of the extension pipe assembly. Remove clamp (11) from the extension pipe and the combustion body (13). Discard clamp (11) as it will be replaced. Disconnect extension pipe assembly from the diesel particulate filter. Refer to Images 1.4.1 and 1.4.2

Image1.4.1

Image1.4.2

7. Remove clamp (12) from combustion body group (13) and turbo. Do not reuse clamp (12). Refer to Image 1.5.1.

Image1.5.1

8. Remove bolts, nuts and washers from the original support bracket. Save the hardware for reuse. Remove combustion body from the engine. Refer to Image 1.4.1.

9. Remove the extension pipe assembly from the chassis. Use appropriate tooling to remove the heat shielding on the original extension pipe assembly.

10. Remove the bolts and washers that hold the heat shield to the combustion body. Save the hardware for reuse.

Install Procedure

1. Use appropriate tooling to remove 6 mm of material from the fuel manifold. Cleanliness is extremely important in this step. Cover all open ports on the fuel manifold. Refer to Image 1.7.1 and Image 1.7.2.

Image1.7.1

Image1.7.2

2. Install the new 328-2728 heat shield to the new 325-3698 combustion body with the hardware remove in step 10 of the removal procedure.

3. Using the new 340-1129 extension assembly as a guide, cut the original extension pipe assembly long enough to slide into the flared end of the new 340-1129 section.

4. Place the long and short sections of the extension pipe back into the chassis. Install the new 325-3698 combustion body (13) and the new 328-4158 support bracket (15). Use the hardware removed in step 7 of the removal procedure for the support bracket. Position new 325-3698 combustion body (13) to the turbo outlet and install new 300-8688 clamp (12). Insure body is position correctly and tighten up all mounting hardware as to not allow any movement. Refer to Image 1.8.1.

Image1.8.1

5. Attach the new 340-1129 (9) extension tube to the 325-3698 (13) combustion body. Attach the remaining section of the original extension pipe assembly to the Diesel Particulate Filter and the 340-1129 (9) section. Make sure no binding or interference is present. Tack Weld the assembly together making sure nothing moves or shifts. Disconnect this newly created pipe assembly from the combustion body (13) and Diesel Particulate Filter. Remove the combustion body and extension pipe assembly from vehicle and finish welding the seam shut. Refer to Image 1.8.1.

6. Re-install the extension pipe assembly back into the chassis. Position new 325-3698 combustion body (13) to the turbo outlet and install new 300-8688 clamp (12). Tighten clamp (12) to a torque of 11 +/- 2 N.m (97 +/- 17 lb in). Attach the new 328-4158 support bracket (15). Refer to Image 1.8.1.

7. Attach the new extension pipe assembly (9) to the combustion body (13) with a new 307-9892 clamp (11). Torque clamp to 12 +/- 1 N.m (106 +/- 9 lb in). Refer to Image 1.8.1.

8. Install flame detection temperature sensor (10). Tighten flame detection temperature sensor to a torque of 45 +/- 5 N.m (33 +/- 3 lb ft). Refer to Image 1.4.1.

9. Install new 340-1135 (7) and 340-1136 (8) heat shields on to the new 340-1129 (9) extension pipe assembly with two 5P-0599 clamps (6). Refer to Image 1.8.1.

10. Apply anti-seize to the threads of studs (8) removed in step 9 of the removal procedure. Install studs (8) with the end that is marked "X" in the Up position. Tighten studs (8) to a torque of 17 +/- 2 N.m (12.5 +/- 1.5 lb ft). Refer to Image 1.9.1.

Image1.9.1

11. Install a new 296-7780 gasket (2) into the new 325-3698 combustion body (13). Install original flanged tube assembly (3) removed in step 9 of the removal procedure. Install a 296-7780 gasket (4) and install combustion head (5) removed in step 5 of the removal procedure. Refer to Image 1.3.1.

12. Apply anti-seize to the threads of the five studs (8) and five nuts (6) removed in step 5 of the removal procedure. Install the four original spacers (7) and one new 8E-9571 spacer. Refer to Image 1.9.1 and Image 1.10.1.

Image1.10.1

13. Tighten nuts (6) in a crisscross pattern to a torque of 23 +/- 3 N.m (17 +/- 2 lb ft). Tighten nuts (6) again in a crisscross pattern to a torque of 28 +/- 7 N.m (21 +/- 5 lb ft). Tighten nuts (6) again in a crisscross pattern to a torque of 28 +/- 7 N.m (21 +/- 5 lb ft). Refer to Images 1.3.1 and 1.10.1.

14. Connect new 289-3926, 289-3927, 289-3928 and 289-3929 hose assemblies (10) to the combustion head and fuel manifold. Install the 300-9558 hose loom (not pictured) Refer to Image 1.2.1.

15. Position the cable assembly and install bolt (9). Connect cable assembly (8). Refer to Image 1.2.1.

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

16. Position clamp (6) and install bolt (5). Tighten bolt (5) to a torque of 3 +/- .5 N.m (27 +/- 5 lb in). Refer to Image 1.11.1.

Image1.11.1

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 1.1.1.

17. Position new 289-3930 Tube As. (1) and new 289-3107 gasket (not shown). Install two new 8T-8442 bolts (2) and tighten clamp assembly (6). Refer to Image 1.1.1.

18. Apply anti-seize to the threads of flame detection temperature sensor (3) and install the sensor. Refer to Image 1.1.1.

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

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