PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST ROCKER ARMS ON CERTAIN C15 TRUCK ENGINES EQUIPPED WITH COMPRESSION BRAKES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST ROCKER ARMS ON CERTAIN C15 TRUCK ENGINES EQUIPPED WITH COMPRESSION BRAKES

Usage:

SEBE8857-04

July 22, 2004
(Revised October 2004)
U-221
TT-17

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST ROCKER ARMS ON CERTAIN C15 TRUCK ENGINES EQUIPPED WITH COMPRESSION BRAKES
1119 1123		PS41632

NOTE: This Program can 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 "PS41632" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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.

NOTE: This Revised Service Letter replaces the July 22, 2004 (Revised September 2004) Service Letter. Changes have been made to the service claim allowance, parts needed, and the rework procedure.

TERMINATION DATE

July 31, 2006

PROBLEM

Excessive compression brake movement can cause the exhaust rocker arms to crack on certain C15 truck engines.

AFFECTED PRODUCT

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Model	Identification Number
C15	BXS1-24464

PARTS NEEDED

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Qty	Part Number	Description
BEFORE AND AFTER FAILURE
9	2572122	BOLT-HEX HEA
AFTER FAILURE
1	8L2777	SEAL-O-RING
1	9L7712	NUT-JAM
1	1049270	BUTTON
6	10R1364	ARM AS-V ROC
1	2213276	ARM AS-V ROC
1	2320253	SCREW-ROCKER
1	1309811	SENSOR

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-24 mos	100%	0*	0	0	0	0
NOTE*: This is at most a 5.5?hr job. Use applicable SMCS codes shown below to claim labors for this service letter.
NOTE: For before failure use: This letter only pays for the additional labor and cost of replacing the bolts and adjusting the valve lash when you are already working under the valve cover for some other reason. All other operations that would have normally been done are not covered by this letter.

LABOR HOUR/SUPPLEMENT BREAKDOWN BY CAB TYPE

After failure:

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SMCS CODE	DESCRIPTION	SC	MC	CV	CO
1123-035	Troubleshoot	0.5	0.5	0.5	0.5
1119-010-ES	R&I Jake	0.6	0.6	0.6	0.6
1123-010-S	R&I Rocker Arm Set	3.9	3.9	3.9	3.9
1123-017	Rocker Arms D&A	0.6	0.6	0.6	0.6
1123-030	Wash	0.3	0.3	0.3	0.3
1123-030	Test	0.3	0.3	0.3	0.3
1921-010	Inlet air temp R&I	0.1	0.1	0.1	0.1

Before failure:

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SMCS CODE	DESCRIPTION	SC	MC	CV	CO
1119-037-BC	Replace Bolts	0.5	0.5	0.5	0.5
1105-025-ES-S	Adjust Lash settings	1.5	1.5	1.5	1.5

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

Different procedures are needed for engines equipped with Pac brakes versus engines equipped with Jacobs brakes. The new bolts used for Jacobs brakes will not fit on Pac brakes. Identify which type of compression brake is on the engine and follow the appropriate procedure.

Pac Brake Only:

Before failure: This procedure should be used when the valve covers need to be removed for any reason, such as normal maintenance. It should only be applied once per engine. It should only be applied on engines equipped with Pac brakes.

Torque each of the four brake mounting bolts on each brake to 150N-m.
Torque the nut on each brake mounting stud to 140N-m
Continue with normal maintenance procedures

After Failure: This procedure should be used after the failure of an exhaust rocker arm.

Replace all 6 exhaust rocker arms with 10R1364 arms per normal procedure as specified in the service manual.
Replace the intake rocker arm for the cylinder with the broken exhaust arm only.
Torque all four of the brake bolts on each brake to 150 N-m.
Torque the nut on each brake mounting stud to 140N-m
Replace the air intake temperature sensor.
Set the slave lash to the proper setting called out in SISweb.

Jake Brake only:

There are 4 bolts on each brake. Three of them need to be replaced by new 257-2122 bolts. The bolt across from the stud should not be replaced. The current washers can be reused.

Inspect to see if bolts have already been replaced. The new bolts (shown in figure 1) have a hex head; the original bolts are 12-point.
Loosen the brake fasteners enough that bolts 1-3 can be removed.
Remove bolts 1-3 and replace them with 257-2122 bolts. Torque the bolts to 50N-m plus a 90-degree turn.

NOTE: Failure to replace the correct bolts may cause loss of brake performance.

Torque Bolt number 4 to 160 N-m DO NOT REPLACE THIS BOLT
Torque the nut on the mounting stud to 140N-m.
Adjust lash settings to the proper value called out in SIS.
Repeat for each brake.

After Failure: This procedure should be used after the failure of an exhaust rocker arm.

Replace all 6 exhaust rocker arms with 10R1364 arms per normal procedure as specified in the service manual.
Replace the intake rocker arm for the cylinder with the broken exhaust arm only.
Replace three of the compression brake bolts on each brake with new 257-2122 bolts. The bolt opposite the stud must remain the current bolt. Consult figure 1 to determine which bolts to replace. Reuse the current washer.

NOTE: It is very important to locate the bolts in the correct holes. Failure to do so may cause loss of brake performance.