PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER, INSPECTION AND POSSIBLE REPLACEMENT OF THE CENTER EXHAUST MANIFOLD, AND SOFTWARE UPDATE ON CERTAIN C9 INDUSTRIAL ENGINES INSTALLED IN CLAAS XERION TRACTORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER, INSPECTION AND POSSIBLE REPLACEMENT OF THE CENTER EXHAUST MANIFOLD, AND SOFTWARE UPDATE ON CERTAIN C9 INDUSTRIAL ENGINES INSTALLED IN CLAAS XERION TRACTORS

Usage:

REBE7392-00

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27Feb2012

U-98

O-92

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER, INSPECTION AND POSSIBLE REPLACEMENT OF THE CENTER EXHAUST MANIFOLD, AND SOFTWARE UPDATE ON CERTAIN C9 INDUSTRIAL ENGINES INSTALLED IN CLAAS XERION TRACTORS
1052 1053 1059 1901 1920 7557		PS43519

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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 "PS43519" 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

28Feb2013

PROBLEM

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The existing 253-7324 Turbocharger and 1924697/">192-4697 Center Exhaust Manifold can fail due to elevated exhaust temperatures on certain C9 Engines installed in Claas Xerion Tractors. This causes cracking and exhaust leaks at the mating surfaces of the turbocharger and center exhaust manifold.

AFFECTED PRODUCT

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Model

Identification Number

JSC08962, 9124, 9154, 9278, 9281, 9303-9305, 9319, 9326, 9334, 9359-9360, 9376, 9378-9380, 9383, 9399, 9415, 9417, 9430, 9508-9509, 9525, 9548, 9564, 9574, 9885, 9910, 9965, 9967, 9986, 10313, 13199, 13201, 17233, 17267, 17269, 17571, 17576, 17607, 17630, 17896, 17915, 17922, 17953, 19844, 19849, 21081, 21373, 21387, 21390, 21401-21402, 21404, 21460, 21748, 21972, 21977-21979, 21983, 22200, 22209, 22215, 22225-22226, 22449-22450, 22453, 22457, 22463, 22725, 22729, 23007, 23069-23070, 23072-23075, 23078-23079

MBD04065, 4254, 5306, 5553, 5556, 6646, 7012, 7179, 7181, 7184, 7188, 7354, 7359, 7361, 7363, 7365, 7371, 7386-7387, 7401, 7403, 7416, 7479, 7488, 7495, 7500, 7504, 7527, 8106, 8113, 8201, 8205, 8207, 8240, 8242, 8260, 8266, 8286, 8410, 8470, 8551, 8587, 9044, 9121, 9124, 9132, 9144, 9152, 9159, 9167, 9179, 9274, 9278, 9661, 9695, 10415, 10437, 10615, 10851, 10855, 10872, 11136

PARTS NEEDED

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Qty	Part Number	Description
1	1P0451	GASKET-TURBO
1	1W4795	NAMEPLATE-TURBO
16	3E8017	LOCKNUT
1	5M6214	PLUG-NPTF
1	5P7530	SEAL-O-RING
12	6V5839	WASHER-HARD
1	8L2779	SEAL-O-RING
4	8T7044	STUD-TAPERLOCK
1	20R0126	TURBO GP-BASIC
12	1163715	STUD-TAPERLOCK
6	1613411	GASKET
1	1924697	MANIFOLD-EXHAUST
1	1978419	GASKET
1	2147568	SEAL-O-RING-STOR
1	2287089	SEAL-O-RING-ORFS
1	3817272	SOFTWARE GP-ELEK
1	ENINFOLAB	ENGINE INFORMATION LABEL
1	LABEL	EMISSIONS LABEL
1	SNPLATE	SERIAL NUMBER PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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.

Acquire all new engine labels prior to completing this service letter.

A software update is required.

Factory Passwords will be required.

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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%
0-10000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-hour job
An inspection of the center exhaust manifold must be completed prior to replacement. A picture must be taken of the center exhaust manifold and a picture of the old emissions label. Attach the pictures to the SIMs report for claim approval. An additional $250.00 will be allowed to cover the cost of the Factory Password. This is only be applied to one claim per engine.

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PARTS DISPOSITION

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

Rework Procedure

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TURBOCHARGER REPLACEMENT:

Refer to Disassembly and Assembly, RENR7460.

1. Replace the old turbocharger with the turbocharger that is listed in the Parts Needed.

2. Remove the line going from the Turbocharger to the waste-gate.

3. Using the 5M-6214 Pipe Plug, plug the orifice of the turbocharger as shown in Image1.1.1. Tighten the plug to 16 Nm.

Image1.1.1

3. Install the 1W-4795 Name Plate over the existing turbocharger name plate using a high temp epoxy or equivalent adhesive.

4. Using a scribe, etch the name plate with the part number 384-8812.

CENTER EXHAUST MANIFOLD - INSPECTION AND POSSIBLE REPLACEMENT:

An inspection of the center exhaust manifold must be completed prior to replacement. A picture of the failed manifold must be attached to the SIMS report.

Refer to the following images:

Failed manifold - Image1.3.1
Good manifold - Image1.3.2

If the center exhaust manifold is failed, install a new center exhaust manifold.

Image1.3.1

Image1.3.2

SOFTWARE INSTALLATION:

Upon completing the hardware update, a software update is required.

1. Using Cat ET, flash the ECM with the 381-7272 Software.

2. After completing the Software Install, it is mandatory to update the FLS and FTS values for the engine. Refer to FLS AND FTS UPDATE in this Rework Procedure.

A new emissions label will be required. Engines that receive the new 381-7272 Software must not leave that geographic region due to strict emissions policies.

Refer to the following instructions to apply for the new labels:

ENGINE LABELS:

1. Begin at the SIS web home page. The address is https://sis.cat.com.

2. From the SIS web home page, select the Engine Technical Marketing Information-TMI link.

3. Once in TMI, input the serial number of the engine into the reference number box and select "serial number" in the drop down menu.

4. Press the Retrieve Data button.

5. Select the "Emissions Data" link.

6. Scroll to the bottom and click the link titled, "Need emissions replacement label-Click Here!? This will direct the user to the Large Power Systems Division Home page.

Image1.5.1

7. Click on the emissions/certification replacement link.

Image1.6.1

8. Complete the dealer name and address information.

Image1.7.1

9. Complete the remaining fields highlighted with a red asterisk.

10. Select Engine Information Label as the label type. Enter the number of this Service letter Program in the field titled "Reason for the replacement label request-". It is also very important to have the engine serial number field completed with the correct information.

Note: Multiple engines can be entered in block 6.

Image1.8.1

Image1.8.2

NOTE: Be sure that the correct shipping information is provided. International requests must have a valid UPS or DHL account number.
NOTE: You will be sent two labels when you place the On-line order for the Engine Information Label. The Engine Information Label and the Serial Number Plate will both need to be installed as directed in the rework procedure.
If you do not receive the Engine Information Label and the Serial Number Plate contact: Global_Engine_Marking@cat.com.

11. Remove the original adhesive label. Properly clean the area, and replace it with the new label and clear overlay.

12 Destroy the old emissions label. Provide a photo of the old emissions label and attach the old emissions label to the SIMS report.

FLS AND FTS UPDATE:

After completing the Software Install, it is mandatory to update the FLS and FTS values for the current engine being reworked. Using the images below, identify the corresponding engine serial number and use the FLS/FTS value stated.