PSP FOR TURBOCHARGER TURBINE WHEEL ON D11N TRACTORS; 776B TRACTORS; 777B TRUCKS; AND 3508 ENGINES (SPARE) - PS4394 - MAI LED US AND CANADA, CACO, COFA, CFEL, COSA
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PSP FOR TURBOCHARGER TURBINE WHEEL ON D11N TRACTORS; 776B TRACTORS; 777B TRUCKS; AND 3508 ENGINES (SPARE) - PS4394 - MAI LED US AND CANADA, CACO, COFA, CFEL, COSA
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.
U-68 A-40 AU-43 E-44 O-58 1052 PS4394 NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4394" as Part Number, "7755" as Group Number, and "96" as Description Code. NOTE: This Program cancels and replaces the January 12, 1988 Service Letter - PS4171, the January 13, 1988 Service Letter - PS4187, and the January 14, 1988 Service Letter - PS4175. All Affected Product previously repaired under any of these Programs should be considered under Group 2.
Termination Date
April 30, 1991
Problem
The turbocharger turbine wheel blades may fail on certain D11N Tractors; 776B Tractors; 777B Trucks; and 3508 Engines (Spare).
Affected Product
Model Identification Number Group 1 - Before Or After Failure (7C1278, 7W9082, And 7W9083 Turbocharger Groups) D11N 74Z1-351, 353-356, 359-363, 383-385, 387, 388, 392, 395-405, 407, 410, 491, 504 776B 6JC1-66 777B 4YC1-469, 477, 482, 494 3NF1-8 3508 99W308, 493, 555, 556, 558,, 566, 590, 592, 618, 636, 637, 670, 677, 678, 702, 712, 719, 748, 778, 783, 784, 790, 797, 802, 808 NOTE: All Affected Product previously repaired per the January 12, 1988 Service Letter - PS4171, the January 13, 1988 Service Letter - PS4187, or the January 14, 1988 Service Letter - PS4175 should be consider under Group 2. Group 2 - Before Or After Failure (9Y1488, And 9Y1489 Turbocharger Groups) D11N 74Z352, 357, 358, 364-382, 386, 389, 390, 391, 393, 394, 406, 408, 409, 411-702 776B 6JC167-78 777B 4YC470-476, 478-481, 483-493, 495-1132 3NF9-42 3508 99W836, 861, 882, 883, 900, 903, 905, 916, 921, 927, 959, 982, 989, 1005, 1031, 1033, 1036, 1037, 1053, 1059, 1071, 1084, 1087, 1095, 1100, 1101, 1137, 1187, 1190, 1192, 1199, 1200, 1240, 1241, 1275-1277, 1280, 1313, 1368, 1407, 1436, 1437, 1444, 1464, 1470, 1481, 1495, 1564, 1584, 1597, 1599, 1602, 1605, 1625, 1638, 1648, 1650-1653, 1695, 1696, 1699, 1714, 1718, 1724, 1730, 1731, 1735, 1738, 1754, 1766, 1770
Parts Needed
NOTE: Quantities shown are per turbocharger. There are two turbochargers on D11N Tractors, 776B Tractors, 777B Trucks, and 3508 Engines (Spare). Group 1 And Group 2 - After Failure Only 1 - 0R6006 Turbocharger Assembly 2 - 5P5700 Seal 1 - 7M7273 Gasket 1 - 7N7559 Gasket 4 - 7N7628 Gasket 1 - 7N8875 Gasket Group 1 - Before Failure And If Not Repaired Under Programs PS4171, PS4187, or PS4175 1 - 0L1351 Bolt 1 - 5M2894 Washer 1 - 7M7273 Gasket-Turbocharger-Manifold 1 - 7N7559 Gasket 4 - 7N7628 Gasket 1 - 7N8875 Gasket 2 - 5P5700 Seal 1 - 7W1944 Retainer 1 - 9Y8270 Housing-Turbo 1 - 9Y8267 Cartridge Group 2 - Before Failure and Affected Producted Updated Under Programs PS4171, PS4187, and PS4175 1 - 2F0808 Screw 1 - 7M7273 Gasket 1 - 9M8911 Collar 3 - 9M8915 Ring 2 - 9M8919 Ring 1 - 6N5004 Bearing 1 - 7N3759 Ring 1 - 7N7559 Gasket 4 - 7N7628 Gasket 1 - 7N8875 Gasket 4 - 9N2036 Plate 1 - 9N2041 Bearing Kit 1 - 9N2046 Spacer 1 - 1P1120 Ring 2 - 5P5700 Seal 1 - 1W4795 Nameplate 1 - 9Y8270 Housing - Turbine 1 - 9Y8268 Shaft & Wheel Assembly
Action Required
Install applicable components listed under Parts Needed. If one turbocharger fails or is reworked prior to failure, update the other turbocharger at the same time.
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. whichever (D/N) (Cost) (C/L) (Sell) comes first ***** Group 1 And Group 2 - After Failure Only ***** D11N Tractors, 776B Tractors, 777B Trucks, ***** and 3508 Engines (Spare) ***** 0-3000 100% 1 0 1 0 0 0-24 mo 3001-6000 33 1/3% .5 0 .5 50% 1 25-36 mo NOTE: This is a 2-hour job per turbocharger. There are two turbochargers per product. NOTE: If there has been a previous repair in which the customer participated, part age 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. ***** Group 1 Before Failure If Not Repaired ***** Under Programs PS4171, PS4187, or PS4175 D11N Tractors, 776B Tractors, 777B Trucks, ***** and 3508 Engines (Spare) ***** 0-3000 100% 1 0 1 0 0 0-24 mo 3001-6000 33 1/3% .5 0 .5 50% 1 25-36 mo NOTE: This is a 2-hour job per turbocharger. There are two turbochargers per product. ***** Group 2 - Before Failure ***** And Before Failure on Affected Product Updated Under Programs PS4171, PS4187, or PS4175 ***** D11N Tractors, 776B Tractors, and 777B Trucks ***** 0-3000 100% 1 0 1 0 0 0-24 mo 3001-6000 33 1/3% .5 0 .5 50% 1 25-36 mo NOTE: This is a 2-hour job to per turbocharger. There are two turbochargers per product. NOTE: If there has been a previous repair in which the customer participated, part age 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. When filing a claim for a spare engine use the following serial numbers as the vehicle serial number: U.S. Dealers - 99Z21 CACO and Canadian Dealers - 99Z621 CofA Dealers - 99Z121 COSA Dealers - 99Z421 CFEL Dealers - 99Z821
Parts Disposition
Any parts removed (with the exception of cores used for Caterpillar Remanufactured parts) can be rendered useless and scrapped immediately upon completion of the repair.
Caterpillar Information System:
PSP FOR REPAIRING CERTAIN 8SU BULLDOZERS ON D8N TRACTORS - PS0447 - MAILED COSA PSP FOR REPAIRING CERTAIN 8SU BULLDOZERS ON D8N TRACTORS - PS0447 - MAILED COSA
PSP FOR REWORKING THE WINCH CONTROLS ON CERTAIN 518 SKIDDERS - PS4421 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA PSP FOR REWORKING THE WINCH CONTROLS ON CERTAIN 518 SKIDDERS - PS4421 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
PSP FOR INSTALLING NEW FUEL INJECTION LINE BRACKETS AND CLAMPS ON CERTAIN D8L TRACTORS, D9N TRACTORS, 589 PIPELAYERS, 631E SCR APERS, 637E SCRAPERS, 657E SCRAPERS, 768C TRACTORS, 769C TRUCKS, 834B TRACTORS, AND 988B LOADERS - PS4428 - MAILED US AND C PSP FOR INSTALLING NEW FUEL INJECTION LINE BRACKETS AND CLAMPS ON CERTAIN D8L TRACTORS, D9N TRACTORS, 589 PIPELAYERS, 631E SCR APERS, 637E SCRAPERS, 657E SCRAPERS, 768C TRACTORS, 769C TRUCKS, 834B TRACTORS, AND 988B LOADERS - PS4428 - MAILED US AND C
PRIORITY - DIFFERENTIAL BEARING CAP BOLTS NEED TO BE TIGHTENED ON CERTAIN 814B WHEEL TRACTORS; 815B AND 816B COMPACTORS; AND 966 E LOADERS - PI3462 - MAILED US AND CANADA, CACO, CFEL, COSA LIMITED COFA PRIORITY - DIFFERENTIAL BEARING CAP BOLTS NEED TO BE TIGHTENED ON CERTAIN 814B WHEEL TRACTORS; 815B AND 816B COMPACTORS; AND 966 E LOADERS - PI3462 - MAILED US AND CANADA, CACO, CFEL, COSA LIMITED COFA
PARTS STOCK ACTION ONLY - HYDRAULIC CYLINDER PISTON NUTS MADE TO THIN DESIGN NEED TO BE REMOVED FROM PARTS STOCK - PI7233 - MAI LED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA PARTS STOCK ACTION ONLY - HYDRAULIC CYLINDER PISTON NUTS MADE TO THIN DESIGN NEED TO BE REMOVED FROM PARTS STOCK - PI7233 - MAI LED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA
Brackets And Clamps Need To Be Installed On The Fuel Lines Group Of Certain D10N Tractors; 651E And 656E Tractors; 773B Trucks; And 992C Loaders Brackets And Clamps Need To Be Installed On The Fuel Lines Group Of Certain D10N Tractors; 651E And 656E Tractors; 773B Trucks; And 992C Loaders
PRIORITY - PARTS STOCK ACTION NEEDED - HOUSINGS NEED TO BE INSPECTED FOR CHIPS AND BEARINGS NEED TO BE REPLACED IN THE RET ARDER AND TRANSFER GEAR GROUP ON CERTAIN 657E SCRAPERS - PI3459 - MAILED US, CANADA, CACO, COFA, COSA - REVISED 4/90 PRIORITY - PARTS STOCK ACTION NEEDED - HOUSINGS NEED TO BE INSPECTED FOR CHIPS AND BEARINGS NEED TO BE REPLACED IN THE RET ARDER AND TRANSFER GEAR GROUP ON CERTAIN 657E SCRAPERS - PI3459 - MAILED US, CANADA, CACO, COFA, COSA - REVISED 4/90
PSP FOR INSTALLING NEW BRAKE PLATES AND DISCS IN CERTAIN D4H, D5H, D6H, AND D7H TRACTORS - PS0432 - MAILED COFA PSP FOR INSTALLING NEW BRAKE PLATES AND DISCS IN CERTAIN D4H, D5H, D6H, AND D7H TRACTORS - PS0432 - MAILED COFA
Product Support Program For Replacing The Cylinder Block On Certain D8L Tractors And 631E Wheel Tractors Product Support Program For Replacing The Cylinder Block On Certain D8L Tractors And 631E Wheel Tractors
PSP FOR INSTALLING A NEW DIFFERENTIAL SEAL ON CERTAIN 631E AND 637E WHEEL TRACTORS - PS4413 - MAILED US, CANADA, CACO, COFA, BRA ZIL, CFEL, COSA PSP FOR INSTALLING A NEW DIFFERENTIAL SEAL ON CERTAIN 631E AND 637E WHEEL TRACTORS - PS4413 - MAILED US, CANADA, CACO, COFA, BRA ZIL, CFEL, COSA
SERVICE LETTER SUPPLEMENT FOR AUGUST 2, 1989 SL - PS4339 - PSP FOR REDUCING BEVEL GEAR AND PINION NOISE AND REDUCING THE RUST BEA RING WEAR ON CERTAIN 56 WINCHES USED ON D6H TRACTORS - MAILED US AND CANADA, CACO, COFA, CFEL, COSA SERVICE LETTER SUPPLEMENT FOR AUGUST 2, 1989 SL - PS4339 - PSP FOR REDUCING BEVEL GEAR AND PINION NOISE AND REDUCING THE RUST BEA RING WEAR ON CERTAIN 56 WINCHES USED ON D6H TRACTORS - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
PSP FOR INSTALLING NEW PISTON RINGS AND CYLINDER LINERS TO REDUCE OIL CONSUMPTION ON CERTAIN CHALLENGER 65 TRACTORS; 235C EXC AVATORS; AND 963 AND 97S LOADERS - PS0434 - MAILED COSA PSP FOR INSTALLING NEW PISTON RINGS AND CYLINDER LINERS TO REDUCE OIL CONSUMPTION ON CERTAIN CHALLENGER 65 TRACTORS; 235C EXC AVATORS; AND 963 AND 97S LOADERS - PS0434 - MAILED COSA
Drain Holes May Need To Be Drilled In The ROPS Of Certain 950E Loaders. Drain Holes May Need To Be Drilled In The ROPS Of Certain 950E Loaders.
SERVICE LETTER SUPPLEMENT FOR MARCH 29, 1990 SL - PI3462 - PRIORITY - DIFFERENTIAL BEARING CAP BOLTS NEED TO BE TIGHTENED ON CERTAIN 814B WHEEL TRACTORS; 815B, 816B COMPACTORS; 966E LOADERS - MAIL US AND CANADA, CACO, CFEL, COSA, COFA SERVICE LETTER SUPPLEMENT FOR MARCH 29, 1990 SL - PI3462 - PRIORITY - DIFFERENTIAL BEARING CAP BOLTS NEED TO BE TIGHTENED ON CERTAIN 814B WHEEL TRACTORS; 815B, 816B COMPACTORS; 966E LOADERS - MAIL US AND CANADA, CACO, CFEL, COSA, COFA
PSP FOR REPLACING FAILED EXHAUST VALVES ON CERTAIN - SEE PAPER COPY FOR APPLICABLE MODELS - PS0452 - MAILED US AND CANADA, CAC O, COFA - REVISED 12/90 PSP FOR REPLACING FAILED EXHAUST VALVES ON CERTAIN - SEE PAPER COPY FOR APPLICABLE MODELS - PS0452 - MAILED US AND CANADA, CAC O, COFA - REVISED 12/90
PSP FOR REPEAT TRACK JOINT FAILURES (LEAKS) ON D8N TRACTORS - PS0430 - MAILED CACO PSP FOR REPEAT TRACK JOINT FAILURES (LEAKS) ON D8N TRACTORS - PS0430 - MAILED CACO
PSP FOR REPAIR OF CRACKS AND REINFORCEMENT OF THE CASE AND FRAME ASSEMBLY ON D5H CUSTOM SKIDDERS - PS4448 - MAILED US, CAN ADA PSP FOR REPAIR OF CRACKS AND REINFORCEMENT OF THE CASE AND FRAME ASSEMBLY ON D5H CUSTOM SKIDDERS - PS4448 - MAILED US, CAN ADA
PARTS STOCK ACTION ONLY - 8D6947 AND 9G5589 SWITCHES NEED TO BE REMOVED FROM PARTS STOCK - PI7234 - MAILED US AND CANADA, CAC O, COFA, BRAZIL, CFEL, COSA PARTS STOCK ACTION ONLY - 8D6947 AND 9G5589 SWITCHES NEED TO BE REMOVED FROM PARTS STOCK - PI7234 - MAILED US AND CANADA, CAC O, COFA, BRAZIL, CFEL, COSA
SERVICE LETTER SUPPLEMENT FOR FEBRUARY 11, 1990 SL - PS0416 - PSP FOR INCREASING THE NUMBER OF DISCS AND PLATES IN THE STE ERING CLUTCH AND BRAKE MODULES ON CERTAIN D9N AND D10N TRACTORS - MAILED CACO, COFA, CFEL, COSA SERVICE LETTER SUPPLEMENT FOR FEBRUARY 11, 1990 SL - PS0416 - PSP FOR INCREASING THE NUMBER OF DISCS AND PLATES IN THE STE ERING CLUTCH AND BRAKE MODULES ON CERTAIN D9N AND D10N TRACTORS - MAILED CACO, COFA, CFEL, COSA
PSP FOR MODIFYING THE LOWER HITCH AND INSTALLING A NEW LOWER HITCH PIN ON 508 SKIDDERS - PS0443 - MAILED US AND CANADA, COS A, LIMITED COFA PSP FOR MODIFYING THE LOWER HITCH AND INSTALLING A NEW LOWER HITCH PIN ON 508 SKIDDERS - PS0443 - MAILED US AND CANADA, COS A, LIMITED COFA
Brake Cylinder Kit Needs To Be Installed In The Service Brake Groups On Certain 966E Loaders Brake Cylinder Kit Needs To Be Installed In The Service Brake Groups On Certain 966E Loaders
PARTS STOCK ACTION ONLY - CERTAIN 6V3965 NIPPLE ASSEMBLIES NEED TO BE REMOVED FROM PARTS STOCK - PI7238 - MAILED US AND CAC O, COFA, BRAZIL, CFEL, COSA PARTS STOCK ACTION ONLY - CERTAIN 6V3965 NIPPLE ASSEMBLIES NEED TO BE REMOVED FROM PARTS STOCK - PI7238 - MAILED US AND CAC O, COFA, BRAZIL, CFEL, COSA
PRIORITY - PARTS STOCK ACTION NEEDED - NEW HYDRAULIC TANK FILL STRAINER NEEDS TO BE INSTALLED ON CERTAIN 834B WHEEL TRACTORS AND 988B LOADERS - PI3469 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA PRIORITY - PARTS STOCK ACTION NEEDED - NEW HYDRAULIC TANK FILL STRAINER NEEDS TO BE INSTALLED ON CERTAIN 834B WHEEL TRACTORS AND 988B LOADERS - PI3469 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA
PSP FOR EXCESSIVE AIR SIDE PLUGGING OF FOLDED CORE RADIATORS IN 980C LOADERS - PS0448 - MAILED US AND CANADA, CACO, COFA, CFE L, COSA PSP FOR EXCESSIVE AIR SIDE PLUGGING OF FOLDED CORE RADIATORS IN 980C LOADERS - PS0448 - MAILED US AND CANADA, CACO, COFA, CFE L, COSA