PRODUCT SUPPORT PROGRAM FOR REPLACING OR COVERING THE EMISSION LEGISLATION LABEL ON CERTAIN C3.3 AND C6.6 ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING OR COVERING THE EMISSION LEGISLATION LABEL ON CERTAIN C3.3 AND C6.6 ENGINES

Usage:

REBE3539-00

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30Apr2008

U-223

A-180

D-177

O-200

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING OR COVERING THE EMISSION LEGISLATION LABEL ON CERTAIN C3.3 AND C6.6 ENGINES
7405 1000 7557		PS42682

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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 "PS42682" 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

30Apr2011

PROBLEM

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The Emission legislation label can degrade or become difficult to read on certain C3.3, C6.6, and C6.6 Tier 3 engines covered by this program.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C3.3	N3C00500-00501, 514, 517, 520
C6.6	N6D00287, 289, 291-296, 407, 414-417, 419-423, 425-426, 428-429, 433-436, 438, 440-464, 466-467, 472-476, 478

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*****Group 2*****
120M	B9C00138, 149, 161, 163-166, 170
12M	B9F00067, 80, 89-90, 97, 110, 112-115, 123, 133-134, 137-139, 142
938H	MJC00070, 72-74, 80, 86, 90-91, 94, 100, 102, 104, 106-110, 112-113
953D	LBP00706-00749, 751-773, 779
963D	LCS00717, 719-720, 722-724, 727-730, 732-735, 737-759, 761, 763, 765-778, 782
CP-563F	C5P00175
CP-573F	C6P00103
CP76	JCP00104
CS-563F	C5S00234, 243, 247, 250
CS-583F	C8S00110
CS76	CYX00108
D6K LGP	DHA00629, 635-636, 638-639, 643-687, 689-701, 704, 706-707, 709-715, 719-720, 723, 726, 729
D6K XL	FBH00790-00798, 800-860
D6N LGP	DJY00885, 897-898, 904-905, 920-923, 925, 927, 930, 933-963, 965-983, 985-1002, 1004-1028, 1030-1037
D6N XL	DJA00662-00663, 668-669, 680-683, 686-690, 693-697, 699-736, 738-739
PL61	WGS00103-00104

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*******Group 3*******

C6.6 TIER 3

66605448, 5465, 5468, 5648, 5676, 5702, 5706, 5708, 5749, 5759, 5800, 5946, 5949, 5952, 5957, 5975, 5977, 5982, 5993, 5996-5997, 6000-6001, 6004, 6029-6030, 6035-6040, 6042-6076, 6078, 6100, 6167-6168, 6220-6222, 6224-6225, 6267, 6270, 6277, 6280, 6284-6285, 6289-6291, 6295, 6300, 6305, 6312, 6320-6325, 6327-6329, 6332-6336, 6338, 6344-6346, 6359-6377, 6402-6404, 6406-6407, 6410-6412, 6437-6449, 6460, 6464-6486, 6491-6492, 6495-6522, 6524-6543, 6545-6557, 6560-6565, 6570-6616, 6619-6635, 6637-6647, 6649, 6651-6662, 6664-6678, 6682, 6690-6691, 6693-6694, 6696, 6704, 6708, 6738, 6742

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*****Group 4*****
924H	HXC00443-00451, 550-560, 562-610, 613-630, 632, 634 JTM00255-00257, 260, 264-265, 267-268, 270-277, 279-283, 602-612
924H Z	PED00263-00264, 268, 275-276, 282-283, 287, 291, 293, 300-304, 307-311, 313, 318, 320-324
928H	BYD00233-00239, 243, 247-251, 253-262 CXK00303-00306, 308-332, 334-337
930H	DHC00391, 394-395, 397-405, 407-409, 600, 602-614, 616-684, 686-687, 690-692, 695-696, 711 FTD00213, 216, 218-224, 227-230, 232-236, 239, 241, 243-248, 650-668, 670-671, 674-677, 679-688
M316D	W6A00717-00718, 721-728, 730-732, 738
M318D	W8P00686-00687, 692-707, 709-710, 712-720, 722-741 W8R00230-00237
M322D	W2S00286-00305, 308-309, 313
M322D MH	W2T00291-00312, 315

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3264474	LABEL-PROT
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	3264474	LABEL-PROT
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 3*****
1	3264474	LABEL-PROT
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 4*****
1	3264474	LABEL-PROT
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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The Emission legislation label on certain machines needs to be cleaned and a clear label fitted over the existing lablel. A replacement label needs to be ordered and attached if the label or the print on the label are damaged. The replacement label will be issued upon request if the label requires to be replaced.

Refer to the attached rework procedure for the method of cleaning, checking, covering, or changing the label.

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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*****
0-2000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 1

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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*****
0-2000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 2

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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 3*****
0-2000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 3

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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 4*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 4

PARTS DISPOSITION

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

Rework Procedure

Legislation Label Check, Removal, and Clear Label Application Process

Recommended tools required: Water, Paper Towel, Heat Gun, Blunt Scraper, Clear label part number - 326-4474.

1. Confirm the Engines serial number is within the affected serial number range of engines to be reworked. At the earliest opportunity or next service carry out the following procedure.

2. Check the engine for the location of the emissions labels. There may be more than one label fitted to each engine; the location could be on either side of the block. Check the machine for additional labels. Additional labels need to be treated in the same manner.

Image 1.1.1 shows typical locations on the side of the block.

Image 1.1.2 shows typical locations where an additional label has been fitted to the top cover of the engine.

Image1.1.1

Image1.1.2

3. If emissions label and surrounding area around the label require cleaning, follow the next steps:

Image1.2.1

3.1. Rinse off label with clean cold water (use a bottle, a hose pipe, or pressure washer). If after rinsing / pressure washing the label is still dirty.

3.2. Wipe label once with a paper towel pre-soaked in water and discard after each use.

Image1.3.1

3.3. Repeat with a new paper towel pre-soaked in water until label and surrounding area is clean. Discard the paper towel after each use.

Image1.4.1

3.4. Place a dry paper towel over the label to draw in the moisture ? DO NOT RUB. Use of a compressed airline to blow / dry the moisture is acceptable.

3.5. If printing / writing is intact and legible, proceed to step 4 (Clear label application method).

Image1.5.1

3.6. If printing / writing is damaged / illegible, proceed to step 5

(Label ordering and replacement).

Image1.6.1

4. Clear label application method:

Remove the clear label from its backing.

Apply clear label over legislation label ensuring there are no air bubbles.
Using a finger, rub down the label, paying special attention around the edges.
Note: Some engines may have casting protrusions (e.g. Casting dates) ensure the clear window is firmly pressed in these areas.

Please note a full 24 hours is required to fully cure the label.

Repeat this process for all legislation labels fitted.

Figure 1.7.1 -

1 Shows a typical label fitted to a 6 cylinder engine.
2 shows the importance of ensuring the label is securely fitted where there is embossed writing on the 6 cylinder block.
3 Shows the arrangement for the 3 cylinder block and the need to ensure the label is securely fitted.

Image1.7.1

5. Replacement Emissions Label Request

Print the form to get the information required to request a replacement label. The form is shown in Image 1.8.1, complete the form. The completed form can be scanned and sent via e-mail, if you have the required software / hardware to:

CPI_Project_186191_Label_rationalisation@cat.com

If you cannot send the whole form electronically the information from the form can be e-mailed to the same e-mail address. It is preferred to attach a Word document similar to the form shown.

The appropriate Legislation representative will deal with your request.

Image1.8.1

If the writing can not be read, order a replacement label, use the process detailed above to obtain the new label and at the earliest opportunity / next service after receiving the label, fit to the affected engine.

Removal process for the label.

Use a heat gun to gently heat entire label by holding gun 3-4 inches away. Be careful not to overheat the label and/or burn the paint.

Image1.9.1

Use a blunt scraper to lift the corner of the label. Be careful not to cut or damage the paint.

Image1.10.1

The label should be able to be removed once heat has been applied ? be sure to do this quickly. The label will become difficult to remove as it cools.

NOTE: The label may not come off in one piece.

Image1.11.1

After the emissions label has been removed, check the area for any excess glue or dirt. Clean the area, if requireed, before applying a new label.

7. Fit replacement emissions label(s) as shown.