PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER ON CERTAIN AP-655D ASPHALT PAVERS, D6K, AND D6N TRACK-TYPE TRACTORS, 924H, 928H, 930H, AND 938H WHEEL LOADERS, AND IT38H INTEGRATED TOOL CARRIERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER ON CERTAIN AP-655D ASPHALT PAVERS, D6K, AND D6N TRACK-TYPE TRACTORS, 924H, 928H, 930H, AND 938H WHEEL LOADERS, AND IT38H INTEGRATED TOOL CARRIERS

Usage:

REBE8493-01

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17Jul2012

(Revised 04Apr2013)

U-378

A-301

D-330

O-347

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER ON CERTAIN AP-655D ASPHALT PAVERS, D6K, AND D6N TRACK-TYPE TRACTORS, 924H, 928H, 930H, AND 938H WHEEL LOADERS, AND IT38H INTEGRATED TOOL CARRIERS
1052 1053		PS52260

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52260" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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 17Jul2012 Service Letter. Changes have been made to the Problem, Action Required, Service Claim Allowances, and Parts Disposition.

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TERMINATION DATE

31Jul2014

PROBLEM

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The existing turbocharger can suffer compressor wheel fractures, a failure which may be attributable to mechanical and/or thermal overloading on certain models and applications under certain operating conditions.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
AP-655D	GNN00200-00267, 269-277, 284, 286, 288 GNZ00200-00442, 444-464
D6K LGP	DHA00207-01101, 1200-1386, 1500-1913, 2000-2210, 2212-2308
D6K XL	FBH00329-01448, 1500-1671, 1800-2271, 2300-2635
D6N LGP	DJY00121-01741 GHS00200-00260, 262-1498
D6N XL	DJA00231-01202 JAH00154-00368 LJR00111-00437, 439, 441, 443-472, 474-523, 525-555, 557, 559, 561, 563, 565-566, 568-639, 641, 643, 645, 647, 649, 651, 653, 655-669, 671-677, 680, 682-683, 685, 687, 689, 691-722, 725, 727-763, 765-848, 853-855, 863 MLW00100-00776

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*****Group 2*****
924H	HXC00200-00451, 550-1620, 1800-3244 JTM00210-00283, 600-840, 842-1113 KLN00230-01461
924H Z	PED00240-01102 WLB00150-01512
928H	BYD00170-00561 CXK00160-00936, 1100-1939, 1941-1943
930H	DHC00180-00409, 600-1882, 2000-4052 FTD00190-00248, 650-1524
938H	JKM00151-02085, 2087-2145 LKM00135-00652, 1000-1965 MCC00138-00666 MJC00038-01906, 11874
IT38H	JNJ00151-00400, 500-711

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	1418589	GASKET-TURBO
2	2779939	WASHER
1	2779940	SEAL-O-RING
1	2780016	GASKET
1	2780017	GASKET
1	3160413	TURBOCHARGER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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	1418589	GASKET-TURBO
2	2779939	WASHER
1	2779940	SEAL-O-RING
1	2780016	GASKET
1	2780017	GASKET
1	3160413	TURBOCHARGER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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This service letter does not apply if the turbocharger compressor wheel has not failed as in Image 1. Remove and inspect the failed turbocharger to determine if the failure mode is due to a fracture of the compressor wheel, see Image 1.

If the compressor wheel has fractured replace the existing turbo with a new 316-0413 Turbocharger. Take a photograph of the failed compressor wheel. Refer to the engine's Disassembly and Assembly manual as necessary.

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Image1

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, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-5000 hrs, 37-60 mo	60.0%	50.0%	0.0%	0.0%	30.0%	50.0%

NOTE: This is a 2.5-hour job for Group 1 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
This service letter does not apply if the turbocharger compressor wheel has not failed. Attach a photograph of the failed compressor wheel within the service claim report.

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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, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-5000 hrs, 37-60 mo	60.0%	50.0%	0.0%	0.0%	30.0%	50.0%

NOTE: This is a 2.5-hour job for Group 2 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
This service letter does not apply if the turbocharger compressor wheel has not failed. Attach a photograph of the failed compressor wheel within the service claim report.

PARTS DISPOSITION

***** NACD *****
Hold all failed 315-9810 Turbochargers for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.

***** EAME, LACD, and APD *****
Hold all failed 315-9810 Turbochargers for 30 days for a possible Parts Return Request (PRR). Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.

If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.