PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST ROCKER ARMS ON CERTAIN C15 AND C16 TRUCK ENGINES EQUIPPED WITH JACOBS 340D COMPRESSION BRAKES

Usage:

SEBE8919

October 1, 2004
U-276
A-191
D-211
O-239
TT-23

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST ROCKER ARMS ON CERTAIN C15 AND C16 TRUCK ENGINES EQUIPPED WITH JACOBS 340D COMPRESSION BRAKES
1123		PS50868

NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS50868" as the Part number and "7755" as the Group Number. 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.

TERMINATION DATE

October 31, 2006

PROBLEM

Excessive compression brake movement can cause the exhaust rocker arms to crack on certain C15 and C16 truck engines.

AFFECTED PRODUCT

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Model	Identification Number
C15	MBN1-99999 6NZ83126-95777
C16	7CZ3834-5150

PARTS NEEDED

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Qty	Part Number	Description
6	10R1364	ARM AS-V ROC
1	10R1365	ARM AS-V ROC
9	2572122	BOLT-HEX HEA
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
Product smu/age whichever comes first	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-24 mos	100%	*	0	0	0	0
*NOTE: This is at most a 5.1?hr job. Use applicable SMCS codes shown below to claim labor.

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	0.5	0.5	0.5
1123-010-S	R&I Rocker Arm Set	2.7	2.1	1.8	2.0
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

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:

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 the 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:

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 compression brake bolts 1-3 on each brake with new 257-2122 bolts. Bolt 4, 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.