PRODUCT SUPPORT PROGRAM FOR REPLACING THE HIGH PRESSURE TURBOCHARGER WASTEGATE ACTUATOR ON CERTAIN 329F, AND 330F EXCAVATORS, 525D, 535D, 545D, AND 555D WHEEL SKIDDERS, 558B FOREST MACHINES, 563D, AND 573D WHEEL FELLER BUNCHERS, 815K SOIL COMPACTORS, Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE HIGH PRESSURE TURBOCHARGER WASTEGATE ACTUATOR ON CERTAIN 329F, AND 330F EXCAVATORS, 525D, 535D, 545D, AND 555D WHEEL SKIDDERS, 558B FOREST MACHINES, 563D, AND 573D WHEEL FELLER BUNCHERS, 815K SOIL COMPACTORS,

Usage:

TEBE5831-02

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23May2017

(Revised 01Aug2017)

U-279

A-184

D-220

O-224

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE HIGH PRESSURE TURBOCHARGER WASTEGATE ACTUATOR ON CERTAIN 329F, AND 330F EXCAVATORS, 525D, 535D, 545D, AND 555D WHEEL SKIDDERS, 558B FOREST MACHINES, 563D, AND 573D WHEEL FELLER BUNCHERS, 815K SOIL COMPACTORS, 816K LANDFILL COMPACTORS, 950, AND 950M WHEEL LOADERS, 963K TRACK-TYPE LOADERS, AP1000F, AND AP1055F ASPHALT PAVERS, MH3037 MATERIAL HANDLERS, AND C7.1 INDUSTRIAL ENGINES
1058 108A 1088 1052 105H 1057 1081 1053 1071 5506		PS45492

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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 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 "PS45492" 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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NOTE:	This Revised Service Letter replaces the 23May2017 (Revised 25May2017) Service Letter. Changes have been made to the attached Rework Procedure. Step 17.3 was added.

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TERMINATION DATE

31May2019

PROBLEM

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The existing 443-0326, 443-0589, 443-0590, 461-1107, 461-1109, or 461-1127 High Pressure Turbocharger can lose wastegate control capability on certain 329F, and 330F Excavators, 525D, 535D, 545D, and 555D Wheel Skidders, 558B Forest Machines, 563D, and 573D Wheel Feller Bunchers, 815K Soil Compactors, 816K Landfill Compactors, 950, and 950M Wheel Loaders, 963K Track-Type Loaders, AP1000F, and AP1055F Asphalt Pavers, MH3037 Material Handlers, and C7.1 Industrial Engines. If the existing high pressure turbo wastegate fails it can lead to the following event codes along with a subsequent machine power derate:

E1044-2 High Intake Manifold Pressure Derate
102-16 Engine Intake Manifold #1 Pressure: High

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
329F L	ERL00115-00865
329F L OEM	GCX00101
330F L	HBT00128-00157, 10001-10038 LCG00134-00138, 10001-10007 MBX00147-00565, 10001-10165 WBA00111-00322, 10001-10017
330F L OEM	B3300101-00104
330F LN	JFR00172-00231, 10001-10028 LBN00171-00398, 10001-10009
330F LN OEM	LNX00101-00114, 10001
330F OEM	B3200101-00107 HA300101
525D	GKP00102-00476
535D	MTP00103-00391
545D	KGP00101-00254
555D	PGY00102-00151
558B LL	LRT00250-00275
563D	D6300100-00114
573D	D7300200-00208
815K	MBB00202-00203, 301-306
816K	WNB00102-00103, 201-212
950 GC	M5T00204-00211, 303-307, 309-311, 313-314
950M	EMB00256-01395, 2101-2697, 3501-3728 FTR00301-00724, 901-1187 HE800250-00315, 10250-10264, 10266 J1S00217, 250-287 XCJ00102-00137, 139-161, 10101-10119, 10121, 10123-10124, 10131-10132, 10134
962M	EJB00171-00333, 501-562, 901-930 F2T00201-00420, 501-608 JYD00101, 103-129, 10101-10114, 10120-10126 SA800250-00261, 10250-10255
963K	LBL00103-00459
AP1000F	AC400103-00308
AP1055F	TJ500105-00589
MH3037	JLH00301, 303-307, 309, 311, 314

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*****Group 2*****
C7.1	88100320-00373, 375-382, 386-523, 525-539, 542-609, 611-718, 720-1288, 1291-1519, 1521-1656, 1658-1700, 1703-1745, 1747-1932, 1934, 1936-2365, 2367-2461, 2464-2504, 2507, 2509, 2515-2516, 2520-2522, 2524-2525, 9999

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	5209956	ACTUATOR AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 10% 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*****
1	5209956	ACTUATOR AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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Before completing the rework procedure, review the safety actions in the Operation and Maintenance Manual.

Refer to the attached Rework Procedure.

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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%
*****Group 1*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-5000 hrs, 25-36 mo	33.0%	100.0%	0.0%	0.0%	50.0%	0.0%

NOTE: This is a 1.5-hour job for Group 1

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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%
*****Group 2*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-5000 hrs, 25-36 mo	33.0%	100.0%	0.0%	0.0%	50.0%	0.0%

NOTE: This is a 1.5-hour job for Group 2

PARTS DISPOSITION

All dealers:
Hold all replaced Wastegate Actuators, complete with circlip, for 30 days for a possible Send It Back (SIB) request. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.

If a SIB request is not issued to you after 30 days through the SIB process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

Rework Procedure

Part & Tooling requirements
? Actuator Kit (5209956)
? Hose, 6.35mm (0.25in) inside diameter to connect hand pressure pump to wastegate can.
? Wastegate Tool kit (215-2592)

Rework instructions

1. Prior to accessing and working on the turbo, please make sure that the machine has been shut down for long enough and engine temperature allows for manual work.

2. Please take a picture of the turbocharger with the wastegate actuator and rod in clear view. Please attach this photo to the service claim submitted in SIMSi.

3. Disconnect the hose assembly from the wastegate actuator.

4. Dismount circlip from pin (Image 1.1.1).

NOTE: Keep circlip available for Send-It-Back requests. See Parts Disposition.

Image1.1.1

5. Connect the wastegate service tool (215-2592) to the wastegate actuator can using hose and then pressurize actuator at 90kPa (13psi); the wastegate crank should move, which will make it easier to disconnect the rod.
Note that if the wastegate actuator has failed, the failed actuator may not move and you should proceed to Step 6.

6. Pull the rod carefully from the pin. Take care not to bend or stress the pin (Image 1.2.1).

Image1.2.1

7. Release pressure from pump, i.e. reduce pressure from actuator to 0kPa (0psi). Remove the pump from actuator.

8. Remove retaining nuts and dismount actuator from bracket (Image 1.3.1).

NOTE: Keep wastegate actuator available for Send-It-Back requests. See Parts Disposition.

Image1.3.1

9. Remove bracket from turbocharger. (Image 1.4.1)

Image1.4.1

10. Mount new bracket on turbocharger and tighten bolts (Image 1.5.1). Tighten to 13.4Nm +/- 1.3Nm. (119 lbin +/- 12 lbin).

Image1.5.1

11. Mount new actuator with old heat shield on bracket; actuator and heat shield orientation to be respected (Image 1.6.1). Fit nuts by a few threads to ensure wastegate does not fall out of bracket.

Image1.6.1

12. Connect wastegate service tool to actuator and pressurize actuator to 90kPa (13psi) to move rod to extended position (Image 1.7.1).

Image1.7.1

13. Mount rod to pin and fit new circlip, supplied with service kit (5209956), with flat side of circlip against the rod (Image 1.8.1).

Image1.8.1

14. Reduce pressure from actuator to 0kPa (0psi). Crank will move as per Image 1.9.1.

Image1.9.1

15. Pressurize actuator at pre-calibration pressure (55kPa +/- 1kPa) (8psi +/- 0.15psi).

16. Push crank to wastegate closed position (Image 1.10.1) ? wastegate must be fully closed ? gap between actuator and bracket will appear (Image 1.10.2).

Image1.10.1

Image1.10.2

17. Spacers need to be fitted into the gap between the heat shield and the bracket. DO NOT force larger spacers into the gap. Apply a suitable cleaning fluid to the spacers.

17.1 Start by fitting the thickest possible spacer. Once no more spacers of this thickness can be fitted, moved to step 17.2.
17.2 Fit the next size down spacer. Once no more spacers of this thickness can be fitted, continue with the next smaller spacer and repeat, until no more spacers can be fitted freely.
17.3 If there is not enough spacers to fill in the gap, this means that the pressure pump is not calibrated properly. Please ensure that the pump is calibrated properly, i.e. within +/- 1kPa (+/- 0.15psi).

The spacer thicknesses are 2mm (0.07874in)(twin circle marking), 1mm (0.03937in)(no marking on spacer), 0.5mm (0.01968in)(triangle marking), and 0.2mm (0.00787in)(square marking).

Image1.11.1

Image1.11.2

Image1.11.3

Image1.11.4

18. Reduce pressure to 0kPa (0psi).

19. Tighten nuts to secure actuator on bracket (Image 1.12.1). Tighten to 2.5Nm +/- 0.5Nm (22 lbin +/- 4 lbin).

Image1.12.1

20. The First check-point: Pressurize actuator to pre-calibration pressure (55kPa (8psi)) and check that crank/wastegate does not move.
If the wastegate moved, please return to Step 15 as a bigger shim may be needed.

21. The Second check-point: Pressurize actuator to calibration pressure (60kPa (8.7psi)) and check that crank/wastegate does move. Actual travel measurements not required but, for information, travel of the rod should be 1mm (0.0394in) @ 60kPa (8.7psi).

22. Once both check points have been successfully complete, reconnect the hose assembly to the wastegate actuator.