PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EMISSIONS VERIFICATION / SERIAL NUMBER LABELS AND REWORKING THE FILTERS FOR DIRECTIONAL FLOW REQUIREMENTS ON CERTAIN DIESEL PARTICULATE FILTERS SOLD INTO CALIFORNIA IN THE YEARS 2010 THROUGH 2013 Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EMISSIONS VERIFICATION / SERIAL NUMBER LABELS AND REWORKING THE FILTERS FOR DIRECTIONAL FLOW REQUIREMENTS ON CERTAIN DIESEL PARTICULATE FILTERS SOLD INTO CALIFORNIA IN THE YEARS 2010 THROUGH 2013

Usage:

TEBE2695-00

07Apr2015


U-155
A-105

 

Priority

  
  

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EMISSIONS VERIFICATION / SERIAL NUMBER LABELS AND REWORKING THE FILTERS FOR DIRECTIONAL FLOW REQUIREMENTS ON CERTAIN DIESEL PARTICULATE FILTERS SOLD INTO CALIFORNIA IN THE YEARS 2010 THROUGH 2013

7557 108F
PI32473
NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32473" 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 "PI32473" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "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.


COMPLETION DATE

TERMINATION DATE

31Oct2015 30Apr2016

PROBLEM

The DPF Emission Verification / Serial Number Labels need to be replaced, and require exhaust flow directional modification be in place on certain Diesel Particulate Filters sold into California in the years 2010 through 2013. The existing DPF Emissions Verification / Serial Number Labels contain incorrect information . Existing DPF arrangements were sold prior to the implementation of standard Caterpillar Serial numbers . The Service Information Management System (SIMS) has been updated with new Caterpillar Serial numbers. Future service information will be tied to these new serial numbers.
Additionally the filters do not have required directional flow modifications in place and require minor modifications to make them compliant.

AFFECTED PRODUCT

Model Identification Number
AFTERTREAT-DPF  ES530032-30066

PARTS NEEDED

Qty

Part Number Description
1 A_RING Ring-A (See Rework Procedure)
1 B_RING Ring-B (See Rework Procedure)
1 C_RING Ring-C (See Rework Procedure)
1 D_RING Ring-D (See Rework Procedure)
1 ENGINE Engine Label (See Rework Procedure)
1 E_RING Ring-E (See Rework Procedure)
1 MODULE Module Label (See Rework Procedure)
2 PIN Pin (See Rework Procedure)
2 PLATE Plate (See Rework Procedure)
1 SYSTEM System Label (See Rework Procedure)
2 TUBE Tube (See Rework Procedure)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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

Caution: Before removing and installing the new labels, allow the DPF to cool to ambient temperature. Failure to do so could expose service personnel to burns and or fire. Refer to the Operation and Maintenance Manual.

Refer to DPF cross reference (Image1.3.1) in the attached Rework Procedure.

STEP ONE
Remove existing DPF Filter Module labels.
Re-install new labels. see Image 1
Install System Serial Number Label. see Image 2
Install Engine Label. see Image 3

STEP TWO
Perform Exhaust Flow Directional Modification. See Rework Procedures A-H.
Record repair into SIMSi using DPF serial number.
Submit service letter claim with engine serial number in notes of
claim.

Refer to the attached Rework Procedure.
Image1
Image2
Image3

OWNER NOTIFICATION

Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%

 NOTE: This is a 4.0-hour job
Note: 4.0 Hrs is allowed for each Filter Module
Note: 4.0 Hrs is allowed for each Filter Module within a Silencer


PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
 
 
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
 
 
 
EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EMISSIONS VERIFICATION / SERIAL NUMBER LABELS AND ADDRESSING REQUIRED DIRECTIONAL FLOW REQUIREMENTS ON CERTAIN DIESEL PARTICULATE FILTERS SOLD INTO CALIFORNIA IN THE YEARS 2010 THRU 2013

MODELS INVOLVED -( DPF ) ES530032-30066

Dear Cat Product Owner:

The DPF Emission Verification / Serial Number Labels need to be replaced,and required Directional Flow Modification put in place on certain Diesel Particulate Filters sold into California in the year 2010 thru 2013 . The existing DPF Emissions Verification / Serial Number Labels contain incorrect information . Existing DPF arrangements were sold prior to the implementation of standard Caterpillar Serial numbers . The Service Information Management System (SIMS) has been updated with new Caterpillar Serial numbers. Future service information will be tied to the new serial numbers on the products listed above .
Additionally these filters do not have required directional flow modification in place and require a minor modification to make them compliant. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service.
The dealer will advise you of the time required to complete this service.
If you are no longer the owner of this product(s), please contact
your local Cat dealer so that our records can be updated. Please
refer the dealer to their Service Letter dated XXXXXXX when
scheduling this service.
We regret the inconvenience this may cause , but urge you to have
this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc. Please refer the dealer to their Service Letter dated 07Apr2015 when scheduling this service.

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



Caterpillar Inc.

Identification #(s)



Attached to 07Apr2015 Service Letter


Rework Procedure


 
Caution: Before removing and installing the DPF, allow the DPF to cool to ambient temperature. Failure to do so could expose service personnel to burns and or fire. Lock Out and Tag Out the master disconnect.
Follow all mandated safety rules. See Image 1.1.1

PROCEDURE FOR SINGLE DPF MODULE

Contact the emissions retrofit Field Service Engineer for the replacement EMISSIONS VERIFICATION / SERIAL NUMBER LABEL .
Steve Cooksey (309)675-0270 Cooksey_Steve_R@cat.com
Brett Johnson (765)448-5537 JOHNSON_BRETT_D@cat.com

Once DPF has cooled to ambient temperature, remove DPF module from exhaust and place in a suitable work area. See Image 1.1.2. Using a grinding wheel, grind off the welds that hold the old module label and remove. Take care to not remove excess material from the outer shell. See Image 1.1.3.

Use 3M scotch brite (or equivalent) to clean up the surface on the locations that the new labels will be placed. Remove protective film from label surface. Form the new labels to match the contour of the DPF so that there are good contact points on all four corners of the labels. Use 308 or 316 stainless steel to tack weld the four corners of the new labels to the component. See Image 1.1.4. When re-labeling is complete Perform Exhaust Flow Directional Modification as per DPF design. ( see Rework Procedures A-G below ) Once rework is complete reassemble DPF assembly to exhaust . Check for any exhaust leaks. Attach replacement engine label in close proximity to engine serial number label. See Image 1.1.5.


PROCEDURE FOR MULTIPLE DPF MODULES

Contact the emissions retrofit Field Service Engineer for the replacement EMISSIONS VERIFICATION / SERIAL NUMBER LABELS .
Steve Cooksey (309)675-0270 Cooksey_Steve_R@cat.com
Brett Johnson (765)448-5537 JOHNSON_BRETT_D@cat.com

Once DPF Silencer has cooled to ambient temperature, remove DPF canister modules from interior of silencer and place in as suitable work area . See Image 1.1.6. Using a grinding wheel, grind off the welds that hold the old label's and remove. Take care to not remove excess material from the outer shell. See Image 1.1.3. Use 3M scotch brite (or equivalent) to clean up the surface in the location that the new label will be placed. Remove protective film from label surface. Form the new label to match the contour of the DPF canister module so that there are good contact points on all four corners of the label's. See Image 1.1.7. Use 308 or 316 stainless steel to tack weld the four corners of the new label to the component. When Re-labeling is complete, Perform Exhaust Flow Directional Modification to all canister modules as per DPF design. ( Rework Procedure H below ) Reinstall DPF canister modules into silencer. See Image 1.1.8.

Attach new system label to outside of silencer. See Image 1.1.9.

Attach replacement engine label in close proximity to engine serial number label. See Image 1.1.5.

Check for any exhaust leaks .
Image1.1.1
Image1.1.2
Image1.1.3
Image1.1.4
Image1.1.5
Image1.1.6
Image1.1.7
Image1.1.8
Image1.1.9
 
PROCEDURES FOR DPF MODULE REWORK

PROCEDURE ( A ) See Image 1.2.1
Butt weld ring flush to retainer ring on the inlet assembly in 4 spots.
Fillet weld (3 mm weld size) 4 tabs (at 0, 90,180 and 270 degrees.

PROCEDURE ( B ) See Image 1.2.2
Butt weld ring flush to retainer ring on the inlet assembly in 4 spots.
Fillet weld (3 mm weld size) 4 tabs (at 0, 90,180 and 270 degrees.

PROCEDURE ( C ) See Image 1.2.3
Butt weld ring flush to retainer ring on the inlet assembly in 4 spots.
Fillet weld (3 mm weld size) 4 tabs (at 0, 90,180 and 270 degrees.

PROCEDURE ( D ) See Image 1.2.4
Butt weld ring flush to retainer ring on the inlet assembly in 4 spots.
Fillet weld (3 mm weld size) 4 tabs (at 0, 90,180 and 270 degrees.

PROCEDURE ( E ) See Image 1.2.5
Butt weld ring flush to retainer ring on inlet assembly in 4 spots.
Fillet weld 2 pins (at 0 and 180 degree orientation) to outlet side of DPF's 300 mm from each other.
Drill 5/8" holes in the outlet assembly flanges 300 mm from each other.
Place tube flush to the flange inside this hole and weld to outlet assembly.

PROCEDURE ( F ) See Image 1.2.6
Position plates (at 0 and 180 degree orientation) to outlet side of the DPF flange.
Allow plates to extend ( minimum 1/4 inch ) past outer edge. Using slots in plates
weld into place.

PROCEDURE ( G ) See Image 1.2.7
Fillet weld (3 mm weld size) 2 pins (at 0 and 180 degree orientation) to outlet side of DPF 260 mm from each other.
Drill a 5/8" hole in the outlet assembly flange 260 mm from each other 13 mm deep.
Place tube flush to the flange inside this hole and weld to outlet assembly.

PROCEDURE ( H ) See Image 1.2.8
Fillet weld 2 pins (at 0 and 180 degree orientation) to outlet side of both DPF's 300 mm from each other.
Drill 5/8" holes in the outlet assembly flanges 300 mm from each other 13 mm deep.
Place tubes flush to the flange inside this hole and weld to outlet assembly.

PROCEDURE ( I ) See Image 1.2.9 and Image 1.2.10
Remove the clamp and gasket from DPF inlet side.
Mate inlet flange to DPF without gasket or clamp.
Tack weld in place.
Apply a continuous weld to the inlet flange/DPF seam.
Image1.2.1
Image1.2.2
Image1.2.3
Image1.2.4
Image1.2.5
Image1.2.6
Image1.2.7
Image1.2.8
Image1.2.9
Image1.2.10
 
Filter Module Cross Reference Guide See Image 1.3.1.
Image1.3.1
 
 

Caterpillar Information System:

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