PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE TURBOCHARGER CARTRIDGE ON CERTAIN 3406E, C15, AND C32 MARINE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE TURBOCHARGER CARTRIDGE ON CERTAIN 3406E, C15, AND C32 MARINE ENGINES

Usage:

REBE5814-01

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08Apr2010

(Revised 28Jul2010)

U-115

A-94

D-101

O-107

TM-7

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE TURBOCHARGER CARTRIDGE ON CERTAIN 3406E, C15, AND C32 MARINE ENGINES
1052 1053		PI31731

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31731" 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 "PI31731" 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:

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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NOTE:	This Revised Service Letter replaces the 08Apr2010 Service Letter. Changes have been made to Rework Procedure for clarification.

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COMPLETION DATE	TERMINATION DATE
31Oct2010	30Apr2011

PROBLEM

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The existing turbocharger cartridge can fail due to a cracked heat shroud. Failure of the cartridge may cause the turbocharger to have insufficient boost pressure and lead to a loss of power.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C32	RXB03123, 3140, 3143, 3158-3160, 3163, 3171, 3173, 3176, 3178-3545, 3547-3642, 3644-3788, 3790-3794, 3798-3825, 3827-3863 SLT00101-00127, 129-161, 163-175, 177-187, 190-194, 196-200, 202-203, 205-210, 213-218, 220-222, 224-228, 230, 236-242, 244

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*****Group 2*****
C32	RNC02457, 2607, 2636, 2643-2644, 2647, 2653-2655, 2660-2662, 2674-2675, 2677, 2680, 2683, 2685, 2687, 2690, 2693, 2695, 2701, 2720-2722, 2724, 2726-3198 RND00100-00160, 165-335, 337 RNE00102-00131, 133-139 RNX00101 RNY00100-00101 T3T00101-00187, 189-195, 198, 200-202, 204-213, 215-222, 225-226, 228-230, 232-233, 236, 241, 243, 246, 252

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*****Group 3*****
3406E	9WR10304-10563, 10583-10673
C15	RLA00578-00873, 879-1051, 1053-1079

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	3E6773	SEAL-O RING
2	6V3917	SEAL-O-RING (After Failure Only)
1	7L4773	SEAL-O-RING (After Failure Only)
1	7M7273	GASKET-TURBO (After Failure Only)
4	8M2296	NUT-FULL (After Failure Only)
1	10R3092	TURBO GP-BASIC (After Failure Only)
2	10R8230	CARTRIDGE GP -A (Before Failure Only)
1	0619456	SEAL-O-RING
2	1123540	SEAL-O-RING
2	1262702	SEAL-INTEGRAL
2	1305694	SEAL-O-RING (After Failure Only)
2	1986068	SEAL-INTEGRAL
1	2054831	SEAL-O-RING (After Failure Only)
2	2264753	GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 35% 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*****
2	3E6773	SEAL-O RING
2	6V3917	SEAL-O-RING (After Failure Only)
1	7L4773	SEAL-O-RING (After Failure Only)
1	7M7273	GASKET-TURBO (After Failure Only)
4	8M2296	NUT-FULL (After Failure Only)
1	10R3092	TURBO GP-BASIC (After Failure Only)
2	10R8230	CARTRIDGE GP -A (Before Failure Only)
1	0619456	SEAL-O-RING
2	1123540	SEAL-O-RING
2	1262702	SEAL-INTEGRAL
2	1305694	SEAL-O-RING (After Failure Only)
2	1986068	SEAL-INTEGRAL
1	2054831	SEAL-O-RING (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 35% 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*****
4	2N2766?	UNKNOWN (After Failure Only)
1	5P7530	SEAL-O-RING
1	6J2245?	UNKNOWN
2	6V3917?	UNKNOWN
1	7M7273	GASKET-TURBO (After Failure Only)
1	10R8230	CARTRIDGE GP -A (Before Failure Only)
1	10R8236	TURBO GP-BASIC (After Failure Only)
1	1142687?	SEAL-O-RING
2	1305694?	SEAL-O-RING
1	1504104?	GASKET
1	2556863	GASKET (After Failure Only)
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

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The turbocharger cartridge needs to be inspected and possibly replaced on certain 3406E, C15, and C32 Marine engines. This program does not apply to Reman turbochargers.

Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 0.5-hour job for Group 1
- 0.5 hours is allowed for the inspection of the turbocharger date codes. - An additional 5.0 hours will be allowed if the turbocharger cartridges meet the criteria for replacement. (Total of 5.5 Hours) - 3.5 hours more will be allowed if the complete turbocharger needs to be replaced due to damage. (Total of 9.0 Hours) Reasonable travel and mileage is authorized. Travel will only be authorized for one engine for multiple engines being reworked in a boat. Please reference the other engine serial numbers in the claim story.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 0.5-hour job for Group 2
- 0.5 hours is allowed for the inspection of the turbocharger date codes. - An additional 5.0 hours will be allowed if the turbocharger cartridges meet the criteria for replacement. (Total of 5.5 Hours) - 3.5 hours more will be allowed if the complete turbocharger needs to be replaced due to damage. (Total of 9.0 Hours) Reasonable travel and mileage is authorized. Travel will only be authorized for one engine for multiple engines being reworked in a boat. Please reference the other engine serial numbers in the claim story.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 0.5-hour job for Group 3
- 0.5 hours is allowed for the inspection of the turbocharger date codes. - An additional 2.5 hours will be allowed if the turbocharger cartridges meet the criteria for replacement. (Total of 3.0 Hours) - 3.5 hours more will be allowed if the complete turbocharger needs to be replaced due to damage. (Total of 6.5 Hours) Reasonable travel and mileage is authorized. Travel will only be authorized for one engine for multiple engines being reworked in a boat. Please reference the other engine serial numbers in the claim story.

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.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE TURBO CARTRIDGE

MODELS INVOLVED - 3406E, C15, and C32 Marine Engines

Dear Caterpillar Product Owner:

The turbocharger cartridge needs to be inspected and possibly replaced on the products listed below. The existing turbocharger cartridge has an internal heat shroud that can crack. You will not be charged for the service performed.

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

Please refer the dealer to their Service Letter dated 08Apr2010 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 08Apr2010 Service Letter

Rework Procedure

Group Number 1 Group Number 2

This rework procedure can be performed before or after failure.

1. Before performing this rework procedure, the turbocharger serial number data tags must be inspected. Reference Image1.1.1 to identify the location of the serial number data tag.

2. Inspect the turbocharger serial number data tag (Image.1.1.1) to determine if the part number of the turbocharger is 287-7210 for the C32.

- If the turbocharger part number IS 287-7210 for the C32, proceed to Step 3.

- If the turbocharger part number IS NOT 287-7210 for the C32, this program does not apply. No further action is required.

3. From the turbocharger serial number data tag, determine the date code of the turbocharger. The date code must match one of those listed in Image1.1.2 in order to qualify for this program.

- If the turbocharger serial number date code matches one of those listed in Image1.1.2, proceed to Step 4.

- If the date code is not listed in Imgage1.1.2, this program does not apply. No further action is required.

4. Inspect the turbocharger for failure or damage.

- If turbocharger has not failed the heat shroud, only the cartridge is to be replaced.

- If the turbocharger has failed the heat shroud but has not damaged the turbine or compressor housing, only the cartridge is to be replaced.

- If the turbocharger has failed the heat shroud and has damaged the turbine or compressor housing, the complete turbocharger is to be replaced under this program.

NOTE: Refer to Disassembly and Assembly instructions RENR8628 for the C32 ACERT and SENR5031 for the C32 HEUI.

Image1.1.1

Image1.1.2

Group Number 3

This rework procedure can be performed before or after failure.

1. Before performing this rework procedure, the turbocharger serial number data tags must be inspected. Reference Image1.1.1 to identify the location of the serial number data tag.

2. Inspect the turbocharger serial number data tag (Image.1.1.1) to determine if the part number of the turbocharger is 130-9725 for the C15/3406E.

- If the turbocharger part number IS 130-9725 for the C15/3406E, proceed to Step 3.

- If the turbocharger part number IS NOT 130-9725 C15/3406E, this program does not apply. No further action is required.

3. From the turbocharger serial number data tags, determine the date codes of the turbochargers. The date code must match one of those listed in Image2.1.1 in order to qualify for this program.

- If the turbocharger serial number date code matches one of those listed in Image2.1.1 continue to Step 4.

- If the date code is not listed in Imgage2.1.1, this program does not apply. No further action is required.

4. Inspect the turbocharger for failure or damage.

- If turbocharger has not failed the heat shroud, only the cartridge is to be replaced.

- If the turbocharger has failed the heat shroud but has not damaged the turbine or compressor housing, only the cartridge is to be replaced.

- If the turbocharger has failed the heat shroud and has damaged the turbine or compressor housing, the complete turbocharger is to be replaced under this program.

NOTE: Refer to Disassembly and Assembly instructions RENR9715 for the 3406E / C15.