PRODUCT IMPROVEMENT PROGRAM FOR REPLACING EXHAUST COMBUSTION GROUPS INCLUDING EXTENSION PIPES ON CERTAIN 2007 C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN FREIGHTLINER CHASSIS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING EXHAUST COMBUSTION GROUPS INCLUDING EXTENSION PIPES ON CERTAIN 2007 C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN FREIGHTLINER CHASSIS

Usage:

REBE3115-03

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14Dec2007

(Revised 19Jun2008)

U-649

A-550

TT-47

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING EXHAUST COMBUSTION GROUPS INCLUDING EXTENSION PIPES ON CERTAIN 2007 C15 ON-HIGHWAY TRUCK ENGINES INSTALLED IN FREIGHTLINER CHASSIS
1061		PI10648

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10648" 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 "PI10648" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the 14Dec2007 (Revised 23Jan2008) Service Letter. Changes have been made to Owner Notification Letter.

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PROBLEM

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This Product Improvement Program is a Safety Recall in accordance with the US National Traffic and Motor Vehicle Safety Act and the Canadian Motor Vehicle Safety Act. The extension pipes attached to the Aftertreatment Regeneration Device (ARD) may develop a crack or hole and heat and flame may escape during a regeneration of the Diesel Particulate Filter, which may result in a fire hazard. It is a violation of US Federal law for a dealer to deliver a new motor vehicle or new or used engine covered by this Safety PIP until the PIP has been completed.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C15	SDP00800-00801, 810, 815, 819, 854, 876, 1260-1263, 1265-1267, 1727, 1799, 1801

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*******Group 2*******

C15

SDP04157, 4334, 4361, 4377, 4426, 4580, 4702, 4712, 4731, 4783, 4797, 4800, 4807, 4812, 4814, 4828, 4837-4839, 4845, 4849, 4854, 4857, 4860, 4868-4869, 4890-4891, 4893, 4901-4903, 4913, 4931, 4936, 4944, 4947, 4952, 4960, 4963, 4970, 4978, 4981-4983, 4986, 5045, 5053, 5057, 5068, 5072, 5077, 5090, 5102, 5120, 5143, 5152, 5178, 5183, 5185, 5190, 5195, 5289, 5296, 5304, 5308-5309, 5312, 5314-5315, 5317, 5328, 5338, 5340-5342, 5353-5354, 5357, 5360, 5716, 5997-5998, 6018, 6029, 6181

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*******Group 3*******

C15

SDP06042, 6066, 6207, 6378, 6384, 6444, 6449, 6455, 6472, 6476, 6485, 6492, 6509, 6514, 6518, 6526-6527, 6544, 6571, 6573, 6579, 6587, 6590, 6593, 6598, 6603, 6609, 6615, 6622, 6630, 6659, 6666, 6820, 6849, 6859, 6871, 6887, 6898, 6969, 7207, 7209, 7227-7228, 7322, 7369, 7392, 7404, 7502, 7569, 7667, 7760, 7972, 8129, 8182, 8206, 8256, 8373, 8466, 8615, 8667, 8672, 8689-8690, 8707, 8713, 8716, 8724, 8731-8732, 8740, 8801, 8804, 8812, 8815, 8824, 8830, 8833-8834, 8839-8840, 8850, 8853-8855, 8871, 8875-8876, 8878-8879, 8884, 8891, 8893-8895, 8897, 8901, 8904-8905, 8908, 8914, 8916-8917, 8922, 8933, 8939, 8942, 8960, 8967, 8980, 8991, 8994, 8997, 9010, 9012, 9017, 9023, 9037, 9051, 9059, 9075, 9090, 9120, 9124, 9131, 9158, 9201, 9212, 9218, 9227, 9236, 9246-9247, 9265, 9280, 9305-9306, 9312, 9385, 9391, 9404, 9440, 9461, 9571, 9594, 9641, 9959, 10085, 10098, 10129, 10179, 10321

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
4	3E4352	WASHER-HARD
2	5P0599	CLAMP-BAND
7	9X8267	WASHER
1	2840671	CLAMP-V-BAND
7	2840761	BOLT-HEX HEAD
2	2890728	NUT-HEX
2	2903930	BOLT-HEX HEAD
5	2914454	SPACER
5	2915204	LOCKNUT-HEX FLG
5	2934967	STUD-TAPERLOCK
2	2967780	GASKET
1	3034326	SHIELD-HEAT (As Required)
1	3034327	SHIELD-HEAT (As Required)
1	3038533	TUBE AS.-AIR
1	3041024	SHIELD-HEAT
1	3041025	SHIELD-HEAT
1	3079892	CLAMP-V-BAND
1	3109305	EXTENSION AS.
1	3110872	BODY-MACHINED
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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.
*****Group 2*****
4	3E4352	WASHER-HARD
2	5P0599	CLAMP-BAND
7	9X8267	WASHER
1	2840671	CLAMP-V-BAND
7	2840761	BOLT-HEX HEAD
2	2890728	NUT-HEX
2	2903930	BOLT-HEX HEAD
5	2914454	SPACER
5	2915204	LOCKNUT-HEX FLG
5	2934967	STUD-TAPERLOCK
2	2967780	GASKET
1	3034326	SHIELD-HEAT (As Required)
1	3034327	SHIELD-HEAT
1	3038533	TUBE AS.-AIR
1	3041024	SHIELD-HEAT
1	3041025	SHIELD-HEAT
1	3079892	CLAMP-V-BAND
1	3109305	EXTENSION AS.
1	3110872	BODY-MACHINED
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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.
*****Group 3*****
2	5P0599	CLAMP-BAND
1	3034326	SHIELD-HEAT (As Required)
1	3034327	SHIELD-HEAT
1	3079892	CLAMP-V-BAND
1	3109305	EXTENSION AS.
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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PRODUCT IMPROVEMENT PROGRAM RECALL NOTIFICATION FOR REPLACING THE AFTERTREATMENT REGENERATION DEVICE EXTENTION PIPE

SERVICE CLAIM ALLOWANCES

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

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NOTE: This is a 8.0-hour job for Group 1
Dealer to perform most economical repair. Description___________________SMCS Code______Hours Wash__________________________107P-074_______0.3 Troubleshooting/ECM Download__107P-035_______0.6 ECM Flash_____________________1901-591_______0.5 Perform rework procedure______108B-010_______6.6 Exception may be allowed depending on chassis type.

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

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NOTE: This is a 8.0-hour job for Group 2
Dealer to perform most economical repair. Description___________________SMCS Code______Hours Wash__________________________107P-074_______0.3 Troubleshooting/ECM Download__107P-035_______0.6 ECM Flash_____________________1901-591_______0.5 Perform rework procedure______108B-010_______6.6 Exception may be allowed depending on chassis type.

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

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NOTE: This is a 6.0-hour job for Group 3
Dealer to perform most economical repair. Description___________________SMCS Code______Hours Wash__________________________107P-074_______0.3 Troubleshooting/ECM Download__107P-035_______0.6 ECM Flash_____________________1901-591_______0.5 Perform rework procedure______108B-010_______4.6 Exception may be allowed depending on chassis type.

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PARTS DISPOSITION

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

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

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IMPORTANT: SAFETY NOTICE

SAFETY ? PRODUCT IMPROVEMENT PROGRAM RECALL NOTIFICATION FOR REPLACING THE AFTERTREATMENT REGENERATION DEVICE EXTENTION PIPE

MODELS INVOLVED - CERTAIN MODEL YEAR 2007 C15 TRUCK ENGINES

Dear Caterpillar Product Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. This notice is also in accordance with the requirements of the Canadian Motor Vehicle Safety Act. Caterpillar has decided that a defect which relates to motor vehicle safety exists in certain Freightliner trucks equipped with Caterpillar C15 truck engines.

The extension pipes attached to the Aftertreatment Regeneration Device (ARD) may develop a crack or hole and heat and flame may escape during a regeneration of the Diesel Particulate Filter, which may result in a fire hazard.

Caterpillar strongly recommends that you not operate the vehicle and contact your Caterpillar dealer immediately to have the extension pipe replaced for the engine serial numbers listed on the attached sheet. You will not be charged for the service performed.

If you are a lessor of these vehicles, you must forward this letter to your lessee within ten days.

If you have had your vehicle repaired for this condition prior to receipt of this notice and incurred any costs, you may be eligible for reimbursement. Please contact Caterpillar at this toll free number (800) 447-4986.

If you no longer own the truck with this engine, please contact Caterpillar at this toll free number (800) 447-4986.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If the dealer is unable to have the inspection and repair made, please contact:

Caterpillar Inc.
PO Box 610
Mossville, IL 61552-610
Attn: Engine Products Division
Truck Engine Call Center
Telephone: (800) 447-4986

If you are unable to have the inspection and repair made within 60 days or without charge, you may submit a complaint to:

In the U.S.
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Avenue, S.E.
Washington, D.C. 20590
Telephone: 1-888-327-4236 (TTY:1-800-424-9153)or go to http://www.safercar.gov

In Canada:
Transport Canada
Road Safety and Motor Vehicle Regulation
Ottawa, Ontario KIA 0N5
Telephone: (613) 993-9851

Please refer the dealer to their Service Letter dated 14Dec2007 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 14Dec2007 Service Letter

Rework Procedure

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Group Number 1

1. Remove combustion body group (ARD) by referencing RENR9706 "Combustion Body Group (ARD) - Removal Procedure".

2. Remove the ARD extension pipe assembly.

3. Install 304-1024 and 304-1025 Heat Shields on the new 311-0872 ARD Body with 284-0761 Bolts and 9X-8267 Washers. Tighten to a torque of 12 +/- 1 Nm. (Image 1.1.1)

Image1.1.1

4. Install combustion head group (ARD) by following steps 1-3 in media RENR9706 "Combustion Head Group (ARD) ? Installation Procedure".

5. Install combustion body group (ARD) by referencing media RENR9706 "Combustion Body Group (ARD) ? Installation Procedure".

6. Replace ARD combustion air tube assembly with replacement PN 303-8533.

7. Install 303-4326 and 303-4327 Heat Shields on the 310-9305 Extension Pipe with 2 5P-0599 Band Clamps and tighten to a torque of 4 Nm +/- 1 Nm.

Image1.2.1

8. Assemble the flared end of extension pipe assembly to the combustion group body with new 307-9892 V-band Clamp. Do not tighten clamp at this time.

9. Align extension pipe with chassis exhaust pipe. Do not tighten OEM supplied v-band clamp at this time.

10. Inspect for interferences with chassis or other components and align piping as necessary.

11. Tighten the 307-9892 V-band Clamp that connects the extension pipe to the combustion body to a torque of 12 +/- 1 Nm.

12. Tighten the OEM supplied v-band clamp that connects the extension pipe to the chassis exhaust according to OEM specifications using a new clamp.

13. Flash Engine Electronic Control Module with the latest software according to SIS web. If SIS web is not available then contact the Truck Engine Call Center. (1-800-477-4986)

14. Perform ARD ignition test in CAT ET.

Group Number 2

Image2.1.1

4. Install combustion head group (ARD) by following steps 1-3 in media RENR9706 "Combustion Head Group (ARD) ? Installation Procedure".

5. Install combustion body group (ARD) by referencing media RENR9706 "Combustion Body Group (ARD) ? Installation Procedure".

6. Replace ARD combustion air tube assembly with replacement PN 303-8533.

7. Replace the extension pipe with a new 310-9305 Extension Pipe.

NOTE: The 303-4326 and 303-4327 Heat Shields are to be replaced with new parts.

NOTE: All in stock replacement pipes have been inspected and are verified for installation.

8. Re-install 303-4326 and 303-4327 Heat Shields on the 310-9305 Extension Pipe with 2 5P-0599 Band Clamps and tighten to a torque of 4 Nm +/- 1 Nm.

Image2.3.1

9. Assemble flared end of extension pipe assembly to the combustion group body with new 307-9892 V-band Clamp. Do not tighten clamp at this time.

10. Align extension pipe with chassis exhaust pipe. Do not tighten OEM supplied v-band clamp at this time.

11. Inspect for interferences with chassis or other components and align piping as necessary.

12. Tighten the 307-9892 V-band Clamp that connects the extension pipe to the combustion body to a torque of 12 +/- 1 Nm.

13. Tighten the OEM supplied v-band clamp that connects the extension pipe to the chassis exhaust according to OEM specifications using a new clamp.

14. Flash Engine Electronic Control Module with the latest software according to SIS web. If SIS web is not available then contact the Truck Engine Call Center. (1-800-477-4986)

15. Perform ARD ignition test in CAT ET.

Group Number 3

1. Remove the ARD extension pipe assembly.

NOTE: The 303-4326 and 303-4327 Heat Shields are to be replaced with new parts.

NOTE: All in stock replacement pipes have been inspected and are verified for installation.

2. Install 303-4326 and 303-4327 Heat Shields on the 310-9305 Extension Pipe with 2 5P-0599 Band Clamps and tighten to a torque of 4 Nm +/- 1 Nm.

Image3.2.1

3. Assemble the flared end of extension pipe assembly to the combustion group body with new 307-9892 V-band Clamp. Do not tighten clamp at this time.

4. Align extension pipe with chassis exhaust pipe. Do not tighten OEM supplied v-band clamp at this time.

5. Inspect for interferences with chassis or other components and align piping as necessary.

6. Tighten the 307-9892 V-band Clamp that connects the extension pipe to the combustion body to a torque of 12 +/- 1 Nm.

7. Tighten the OEM supplied v-band clamp that connects the extension pipe to the chassis exhaust according to OEM specifications using a new clamp.

8. Flash Engine Electronic Control Module with the latest software according to SIS web. If SIS web is not available then contact the Truck Engine Call Center. (1-800-477-4986)

9. Perform ARD ignition test in CAT ET.