PRODUCT SUPPORT PROGRAM FOR THE REPLACEMENT OF THE LOW PRESSURE ACTUATORS (LPA) FOR THE INTAKE VALVE ON CERTAIN C11 AND C13 TRUCK ENGINES
Usage:
REBE2110-00
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| 13Jul2007 |
B020
B090
B130
B150
B160
B190
B270
B274
B290
B330
B360
B370
B420
D070
D090
D100
D241
D250
D310
D390
D430
D440
D480
D490
D530
E140
E250
E310
E330
E459
E490
E500
H070
H200
H273
H370
H380
H81Y
N020
N030
N050
N120
N140
N73R
Z782
Z786
Z889
B090
B130
B150
B160
B190
B270
B274
B290
B330
B360
B370
B420
D070
D090
D100
D241
D250
D310
D390
D430
D440
D480
D490
D530
E140
E250
E310
E330
E459
E490
E500
H070
H200
H273
H370
H380
H81Y
N020
N030
N050
N120
N140
N73R
Z782
Z786
Z889
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| Before/After (Limited distribution) | PRODUCT SUPPORT PROGRAM FOR THE REPLACEMENT OF THE LOW PRESSURE ACTUATORS (LPA) FOR THE INTAKE VALVE ON CERTAIN C11 AND C13 TRUCK ENGINES |
|
| 1130 | PS42458 |
|
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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 "PS42458" 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 |
| 31Jul2008 |
PROBLEM
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| "VVA Not Responding" faults are ocurring on certain C11 and C13 Truck Engines. This failure results in the check engine lamp being illuminated and possible engine derate. |
AFFECTED PRODUCT
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| Model | Identification Number |
| C13 | KCB51532-51533, 51557, 51592, 51605-51606, 51608, 53397, 53419, 53435, 53440, 53450, 53461, 53471, 53490-53491, 53523, 53536, 53542, 53546, 53555, 53560, 53575, 53581, 53585, 53588, 53600, 53616, 53626, 53642, 53655, 53660, 53666-53667, 53691, 53706, 53716, 53720, 53726, 53737-53738, 53757, 53759, 53766-53767, 53781, 53795, 53797, 53805, 53811, 53869, 53900, 53917, 53919, 54015-54016, 54019, 54116, 54679, 54698, 54867, 54876, 55047-55048, 55056, 55063, 55076, 55598, 55682, 55898, 55964, 55997, 56169, 56173, 56188, 56396, 56824, 56845, 56850, 56877, 56884, 56886, 56911-56912, 56939, 56993, 56996, 57011, 57043, 57101-57103, 57108-57109, 57111, 57113, 57115-57116, 57119, 57122, 57125-57126, 57132-57133, 57136-57137, 57144-57145, 57176, 57184, 57186, 57204, 57210, 57224, 57230, 57265, 57276, 57283, 57319, 57328, 57331, 57393, 57396, 57404, 57416, 57534, 57569, 57585, 57600, 57637, 57661, 57681, 57730, 57813, 57819, 57838, 57881, 57887, 57890, 57895, 57904, 57935, 57938, 57944, 57948, 57957, 57965, 57984, 57991, 57998, 58005, 58025, 58027-58028, 58035, 58047, 58049, 58055, 58115, 58129, 58134, 58179, 58197, 58211, 58229, 58289, 58295-58296, 58311, 58333, 58339, 58364, 58394, 58404, 58423, 58441, 58455, 58465, 58488, 58493, 58502, 58559, 58569, 58582, 58595, 58608, 58621, 58638, 58641, 58660, 58688, 58701, 58705, 58709, 58718, 58723, 58741, 58759, 58780, 58785-58786, 58802, 58806, 58819, 58821, 58825-58826, 58839, 58843, 58861, 58889, 58916, 58924, 58937, 58949, 58951, 58970, 58978, 58993, 59008, 59014, 59026, 59063, 59090, 59109, 59131, 59137, 59150, 59153, 59159, 59177, 59204, 59225, 59255, 59289, 59299, 59313, 59490, 59594, 59679, 59689-59690, 59721, 59802, 60423, 60459, 60545, 60547, 60743, 60763, 60800, 60830, 60844, 60897-60898, 60914, 60918-60919, 60930, 60937, 60943, 60980, 61014, 61031, 61036-61037, 61054, 61071, 61093, 61102, 61114, 61125, 61134, 61318, 61340, 61374, 61387, 61391, 61419, 61421, 61427, 61459, 61472, 61481, 61486, 61495, 61513, 61531, 61538, 61542, 61559-61560, 61600, 61709, 61739-61740, 61759, 61777, 61808, 61820, 61841, 61852, 61910, 61954, 61967, 62041, 62049, 62130, 62144, 62189, 62194, 62209, 62227, 62246, 62261-62262, 62265-62268, 62270-62272, 62344, 62353, 62414, 62550, 62665, 62715, 62736, 62768, 62785, 62789, 62897, 62907, 62934, 62951, 62963, 62966-62967, 62974, 62977, 63088, 63124, 63135, 63168, 63192, 63198, 63203-63204, 63207, 63209, 63213, 63219, 63255, 63264, 63315-63316, 63334, 63387, 63389, 63416, 63425, 63455, 63460, 63479, 63485-63486, 63490, 63499-63500, 63506, 63516, 63541, 63568, 63575, 63588, 63615, 63624, 63648, 63653, 63670, 63673, 63675, 63702-63703, 63706, 63708, 63710, 63742, 63748, 63773, 63781, 63796-63797, 63830, 63917, 63953, 63958, 63968, 64001, 64036, 64049, 64122, 64128, 64131, 64135, 64144, 64166, 64195, 64198, 64207, 64245, 64253, 64303, 64322, 64339, 64341, 64356, 64374, 64425, 64427, 64430, 64468, 64489, 64492, 64507, 64551, 64559, 64584, 64591, 64629, 64671, 64682, 64696, 64702-64703, 64705, 64708, 64717, 64733-64736, 64770, 64788, 64790-64791, 64795, 64799, 64831-64833, 64837, 64843, 64845-64846, 64850, 64854, 64861, 64870, 64891, 64900, 64902, 64917, 64930, 64934, 64960-64961, 65106, 65123, 65145, 65187, 65202, 65222, 65232, 65266, 65309, 65321, 65363, 65387, 65418, 65436, 65454, 65481, 65501, 65505, 65511, 65518, 65532, 65537, 65550, 65559, 65564, 65593, 65596, 65620, 65627, 65631, 65658, 65666, 65670, 65673, 65679, 65682, 65711, 65715, 65724, 65739, 65749, 65752, 65773, 65781, 65801, 65860, 65865, 65898, 65905, 65949, 65968, 66010, 66016, 66043, 66056, 66068, 66078, 66085-66086, 66092, 66096, 66109, 66118, 66141, 66147, 66159, 66182, 66208, 66218, 66223, 66240, 66273-66274, 66285, 66298, 66309, 66312, 66315-66316, 66320, 66326, 66351, 66396, 66402, 66439, 66443, 66460, 66484, 66486, 66538, 66603, 66630, 66827, 66840, 66859, 66867, 66879, 66900, 66908, 66927, 66978, 67163, 67451, 67476, 67485, 67503, 67513, 67554, 67581, 67608, 67622, 67636, 67687, 67692, 67791, 67800, 67822, 67960, 68098, 68143, 68163, 68341, 68372, 68393, 68396, 68422, 68446, 68454, 68476-68477, 68483, 68493, 68500, 68528, 68537, 68548, 68565, 68601, 68638, 68686, 68736, 68744, 68750, 68820, 68862, 68917, 68920, 69013, 69042-69043, 69068, 69075, 69089, 69129, 69166, 69180, 69223, 69287, 69326, 69337, 69367, 69370, 69411, 69468, 69496, 69511, 69525, 69553, 69585, 69628, 69645, 69664, 69682, 69688, 69693, 69701, 69725, 69730, 69736-69737, 69757, 69764-69765, 69780, 69791, 69794, 69796, 69843, 69849, 69883, 69905, 69910, 69920, 69979, 70000, 70018, 70059, 70095, 70107, 70114, 70127, 70140-70141, 70249, 70263, 70334, 70360, 70414, 70566, 70574, 70765, 70767, 70774, 70826, 70903, 70917, 71002, 71204, 71253, 71381, 71399, 71424, 71439, 71441, 71500, 71504, 71506-71507, 71543, 71545, 71559, 71568, 71600, 71605, 71615, 71626, 71725-71726, 71786, 71791, 71793, 71834, 71842, 71886, 71972, 71990, 72088, 72189, 72197, 72207, 72218, 72281, 72327, 72331, 72347, 72352, 72391, 72422, 72438, 72446, 72448, 72453, 72505, 72572, 72574-72576, 72579, 72586, 72588, 72590, 72592, 72660, 72666, 72668, 72694, 72783, 72816, 73031, 73076, 73162-73164, 73179, 73214, 73289, 73402, 73435-73436, 73440, 73450, 73455, 73510-73511, 73545, 73549, 73644, 73732, 73928, 73986, 74019-74020, 74163-74164, 74226-74229, 74252, 74312, 74369, 74374, 74504, 74653, 74655, 74657, 74911, 74914, 74940, 74942, 75314, 75343, 75359, 75370, 75408-75409, 75471, 75513, 75639-75641, 75784-75785, 75887, 75968, 75971, 76244, 76311, 76314, 76485-76489, 76646-76649, 76790, 76792, 76869, 77073, 77189, 77191, 77290, 77384, 77573, 77691, 77767-77770, 77781, 77803, 77893, 77917, 77960, 78004, 78063, 78109, 78157, 78249, 78252, 78273, 78275, 78328-78333, 78339, 78499-78503, 78527-78528, 78547, 78549, 78554, 78564, 78613-78614, 78621, 78627, 78741-78742, 78745, 78748, 78775-78776, 78849, 78875, 78877-78878, 78939, 78942, 79009, 79013, 79127, 79129-79131, 79239, 79249, 79278-79280, 79406, 79445, 79510, 79547, 79562, 79687, 79744, 79873, 79876, 79943-79944, 80037, 80059, 80069, 80071, 80094, 80165, 80173, 80184, 80203, 80228, 80237, 80336, 80438-80440, 80590, 80592, 80599-80600, 80709, 80758-80760, 80806, 80858, 80907, 80927, 80973-80977, 80994-80995, 80997, 81075-81078, 81133-81134, 81151-81154, 81178, 81181, 81183, 81201, 81227, 81246, 81326-81329, 81337, 81342, 81360, 81445, 81464, 81476, 81479, 81501, 81527, 81543, 81564, 81591, 81609, 81663, 81712, 81725, 81735, 81745, 81797, 81828, 81830, 81939, 82628-82630, 82920-82921, 83002, 83033, 83060, 83067, 83220, 83271, 83307, 83431, 83461, 83588, 83606, 83643, 83660, 83675, 83734, 83768, 83789, 83844, 84030, 84043, 84062, 84110, 84118, 84141, 84154, 84177, 84229, 84245, 84259, 84343, 84356, 84466, 84470, 85479, 85481, 85735, 85800, 85820, 85838, 85847, 85866, 85901, 85909, 85948, 85956, 85975, 85990-85991, 86008, 86011-86012, 86034, 86065, 86077, 86088, 86125, 86139, 86169, 86183, 86197, 86204, 86220, 86227, 86234, 86251, 86276, 86281, 86283, 86302, 86314, 86321, 86330, 86357, 86375, 86409, 86422, 86425, 86435, 86463, 86468, 86471, 86502, 86508, 86511, 86522, 86592, 86627, 86634, 86637-86639, 86648, 86663, 86667, 86683, 86701, 86727, 86737, 86751, 86758, 86777, 86782, 86803, 86809, 86817, 86823, 86832, 86857, 86884, 86892, 86905, 86911, 86931, 86938, 86946, 86952, 86958, 86979, 87039, 87049, 87067, 87092, 87111, 87132, 87137, 87172, 87190, 87197, 87240, 87246, 87256, 87290, 87301, 87336, 87350, 87355, 87360, 87371, 87385, 87396, 87432, 87443, 87450, 87467, 87499, 87514, 87561, 87567, 87574, 87641, 87648, 87660, 87668, 87677, 87727, 87732, 87755, 87758, 87776-87778, 87788, 87808, 87816, 87827, 87870, 87891, 87898, 87921, 87929, 87947, 87987, 87992, 88010, 88034, 88038, 88049, 88071, 88081, 88092, 88124, 88179, 88187, 88263, 88341, 88365-88366, 88410, 88556, 88579, 88586, 88769, 88819, 88829, 88844, 88917, 88935, 88985, 88987, 88997, 89030, 89055, 89109, 89115, 89148, 89167, 89176, 89292, 89377, 89403, 89434, 89447, 89540, 89601, 89615, 89638, 89650, 89707, 89757, 89800, 89855, 89902, 89909, 89924, 89963, 90050, 90085, 90093, 90130-90132, 90342, 90367, 90394, 90419, 90480-90481, 90620, 90644, 90657, 90673, 90709, 90715, 90731, 90768, 90798-90799, 90801-90805, 90807-90809, 92999 |
PARTS NEEDED
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Qty |
Part Number | Description |
| 3 | 3032439 | KIT-ACTUATOR |
ACTION REQUIRED
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| This service letter will address the replacement of ALL 1 piece Low Pressure Actuators (LPA) on the engine. The Service Letter will allow you to apply 0.7 hour to an engine that already have 2 piece LPA's on the engine. Refer to the attached Rework Procedure for installation of the 2-piece LPAs. Only replace the 1 piece LPAs on the engine. The 303-2439 Actuator Kit contains (2) 2-piece LPAs. Check your engine before ordering. Each engine rework may require between 1 and 3 kits depending on how many 1 piece LPAs are already installed on the engine. Image 1 shows the difference between the 1-piece LPA and 2-piece LPA. This Service Letter will allow 0.7 hours for inspection time on engines that are determined to already have the two piece LPA's installed. |
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|
| Image1 |
SERVICE CLAIM ALLOWANCES
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0-36 mo |
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| NOTE: This is a 2.0-hour job | ||||||
| This Service Letter will allow 0.7 hours for inspection time on engines that are determined to already have the two piece LPA's installed. This Service Letter does not allow for the replacement of 2 piece LPA's |
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PARTS DISPOSITION
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| Return all parts to: Engineering Parts Return Area CATERPILLAR_INC.,__BUILDING_DD,_DOCK_8__ATTN: Joshua Evans ROUTE_29_&_OLD_GALENA_ROAD MOSSVILLE, ILLINOIS_ 61552 |
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| Tool List 1. 247-5377 torque screwdriver (compact T-handle) capable of 2.3 +/- 0.2 N-m (20.4 +/- 1.8 pound inches) for 3 mm valve screw removal/installation 2. 10 IP Torx plus driver 3. 6 IP Torx plus or T6 Torx for 2 mm carrier screw removal. 4. 222-3124 Electrical Component Cleaner Potential Source of Tools: (Wiha Quality Tools, http://www.wihatools.com) 1. Wiha torque-vario-s 7 piece kit number 28598. This includes a 10-IP driver bit and tool for setting the torque to 20 in-lbs. Replacement torque driver number is 285-06. 2. Wiha 6-IP and 10-IP driver bit number 28572 and 28576. This works with the torque-vario-s driver. Actuator Kit contains: (8) 221-9939 Screw M3 x 0.5 (2) 221-9895 Actuator Gp (Images are for illustration purposes. The work is intended to be completed with actuator housings remaining installed on the engine.) 1. Remove valve cover from engine. 2. Remove old valves from the Actuator, image 1.1.1 and 1.1.2. Do not un-bolt VVA housings from cylinder head. Unplug solenoid valve from wire harness, image 1.6.1. Remove 4 screws (M3) using 10 IP Torx plus insert tool. Remove valve from assembly. Send removed one piece LPA valves back using claims return. Do not reuse the old M3 screws. |
|
| Image1.1.1 |
|
| Image1.1.2 |
| 3. Clean valve mounting surface using Electrical Component Cleaner, image 1.2.1. Surfaces must be kept clean. |
|
| Image1.2.1 |
| 4. Install new M3 screws into valve from kit, image 1.3.1. There are four screws per valve. Check to make certain screws drop down freely and have no binding. If binding is noticed, then loosen the two M2 carrier screws; turn using the 6 IP torx plus tool and do not retighten. |
|
| Image1.3.1 |
| 5. Install each new valve, image 1.4.1 and 1.4.2. Orient the connector and screw holes. The valve must be oriented as shown in figures by rotating the valve assembly such that the black wire harness connector appears as the figures and the screw holes line up with tapped holes in the housing. Snug the M3 screws down in a cross pattern 1-2-3-4, image 1.4.3. Use 10 IP Torx plus tool. Note: All the M3 screws need to be snugged down prior to torquing. |
|
| Image1.4.1 |
|
| Image1.4.2 |
| 6. Final torque of each valve. Torque the four M3 screws to 2.3 +/- 0.2 N-m (20.4 +/- 1.8 pound inches) in a cross pattern 1-2-3-4, image 1.4.2. Note: Failure to insure that screws do not bind and/or improper torquing process can cause actuator not responding faults. 7. Remove two M2 carrier screws per valve, image 1.5.1. Use the 6 IP Torx plus or T-6 Torx tool. Note: Failure to remove these screws may cause them to become loose during engine operation and result in damage. The M2 carrier screws need to be screwed in to the old valves being sent back through the claims process. |
|
| Image1.5.1 |
| 8. Plug wire harnesses into both valve connectors, image 1.6.1. Note: The bail clips that hold the wire harness to the valve must be fully latched. |
|
| Image1.6.1 |
| 9. Repeat steps 2 through 8 for remaining cylinders. 10. Re-assemble engine. 11. Run Intake Valve Actuator Response Test SMCS - 5479-038-IL to confirm VVA operation. |
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PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DISCRETE I/O MODULES AND/OR ITS MOUNTING GROUP ON CERTAIN 3516B AND 3516C 60HZ GENRATOR SETS PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DISCRETE I/O MODULES AND/OR ITS MOUNTING GROUP ON CERTAIN 3516B AND 3516C 60HZ GENRATOR SETS
PRODUCT IMPROVEMENT PROGRAM FOR MISSING SHIPPED LOOSE PARTS ON MOUNT AS. (232-0536) ON CERTAIN C32 MODELS PRODUCT IMPROVEMENT PROGRAM FOR MISSING SHIPPED LOOSE PARTS ON MOUNT AS. (232-0536) ON CERTAIN C32 MODELS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL LINE SUPPORT BRACKETS AND HARDWARE ON CERTAIN 3516BHD LOCOMOTIVE ENGINES PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL LINE SUPPORT BRACKETS AND HARDWARE ON CERTAIN 3516BHD LOCOMOTIVE ENGINES