PRODUCT IMPROVEMENT PROGRAM FOR UPDATING CERTAIN C15 ON-HIGHWAY TRUCK ENGINES Caterpillar

PROBLEM

AFFECTED PRODUCT

PARTS NEEDED

Please have the serial number of the engine and the customers name available when calling for the parts kit.

ACTION REQUIRED

OWNER NOTIFICATION

SERVICE CLAIM ALLOWANCES

PARTS DISPOSITION

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
        (2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

PRIORITY - Update Kit Available

MODELS INVOLVED ? C15 On-Highway Engines

Dear Caterpillar Product Owner:

An Update kit customized specifically for your C15 On-Highway Engine is available for the products listed below. This kit will provide various updates including new engine software. Installation of this update kit will provide the ability to obtain future engine software enhancements should they become available. You will not be charged for the service performed.

Contact your local Caterpillar dealer to schedule this service. Since the kits are engine serial number specific, contact your dealer in advance to allow time for obtain your specific kit. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated May 17, 2004 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible.

Attached to May 17, 2004 Service Letter

Use the chart below to determine which group the engine falls into:

1. Follow M4X1136 instructions to install a new engine information label.
1. Remove/destroy the current Engine information label (a small 2" by 4.5" silver label located on the left-hand side of the valve cover base.
2. Install the new engine information label provided in the kit.
NOTE: The labels are serial number specific and should match the engine?s serial number. If the numbers do not match, do not install and then please call for assistance.
2. Follow M4X1134 instructions to update engine software. Included in the kit is a CD programmed with Field Update Assistant. This program will guide you through the process to update the software on your engine.
1. This program should run automatically when the CD is inserted in the CDROM drive. If It does not, open "My Computer ->Compact Disc" and click on CAT_C15_ACERT_UPDATE.EXE. If this program generates error messages and fails to run please run the SETUP.EXE file located on the disc and then look in your START MENU to launch the program.
2. The software should guide you through the following steps.
1. Verify that you have the required service tool software.
2. Enter current engine information.
3. If required, enter injector serial numbers. This step may not be needed for some engines.
4. Update ECM personality Module using Caterpillar Electronic Technician.
5. Update Injector Trim Files using Caterpillar Electronic Technician.
3. Install new FLS/FTS settings.

1. Complete all steps outlined for Group A.
2. Follow M4X1085 instructions to replace 4 bolts, spacers and washers on the Low pressure Turbo Support Bracket

 

 
 
 

NOTE: The spacers, bolts, and washers are not required on the center two bolts of the six hole bolt pattern on the bracket.

3. The bolts should be tightened to a torque of 35 ± 5 N.m.

               Group C:

1. Complete all steps outlined for groups A and B.
2. Follow M4X1086 instructions to repair or replace the turbo to manifold gasket joint. If this repair has already been done, it is not necessary to do it again.
1. If leakage is minimal and gasket appears intact retighten to a torque of 55 ± 5 N.m.
2. If gasket is replaced
1. Remove turbo, replace old gasket with (1) 2436462 Gasket.
2. Lubricate nut washer face and stud threads with 1E2078 Anti-seize compound.
3. Replace turbo and tighten the turbo stud nuts to a torque of 55 ± 5 N.m.
3. Ensure the correct 1687800 Nut is installed on the stud.

        Group D:

1. Complete all steps outlined for Group C.
2. Install a new EPA label

1. Remove/destroy the current EPA label (located on the oil cooler).
2. Install the new EPA label provided in the kit.

1. Follow M4X1083 or M4X1084 to update the air compressor lines.
1. Before installing chamber, check it for debris as outlined in PS41546.

1. Complete all steps outlined for Group D.
2. While completing M4X1086 - Turbo gasket update replace the studs with (4) 2384665 Studs:
1. Remove turbo, replace studs with (4) 2384665 Studs, torque to 35 ± 5 N.m and (1) 2436462 Gasket
2. Lubricate nut washer face, stud threads, and bolt with 1E2078 Anti-seize compound.
3. Torque turbo stud nuts to 55 ± 5 N.m.

1. Complete all steps outlined for Group E.
2. Follow M4X1087 instructions to install a shield on the Exhaust manifold.

If an engine is in Group G ONLY

1. Replace current water pump cover and radiator hose with new hose, cover, and clamps provided in the kit.
2. Tighten hose clamps to 55 ± 5 in-lbs.

1. Complete all work as outlined for that group in the directions above.
2. Complete steps 1-2 above.