PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW ENGINE SOFTWARE AND REWORKING THE TURBOCHARGER WASTEGATES ON C32 ENGINES INSTALLED IN CERTAIN 777F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW ENGINE SOFTWARE AND REWORKING THE TURBOCHARGER WASTEGATES ON C32 ENGINES INSTALLED IN CERTAIN 777F OFF-HIGHWAY TRUCKS

Usage:

REBE4561-00

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25Nov2008

U-601

A-497

D-512

O-551

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Priority Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW ENGINE SOFTWARE AND REWORKING THE TURBOCHARGER WASTEGATES ON C32 ENGINES INSTALLED IN CERTAIN 777F OFF-HIGHWAY TRUCKS
1052 1920 1057		PI31588

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31588" 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 "PI31588" 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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COMPLETION DATE	TERMINATION DATE
31May2009	30Nov2009

PROBLEM

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The existing software and wastegate setting can lead to high exhaust temperatures which can lead to unexpected downtime from turbocharger failures and exhaust manifold failures.

AFFECTED PRODUCT

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Model	Identification Number
777F	JRP00277-00287, 289-369, 371-376, 379-380, 382-386, 388-389, 391-429, 431-436, 438-441, 443-584, 586-634, 636-709, 713-725, 727-733, 735-757, 759-783, 785-806, 809-825, 827-846, 848-851, 855, 857-860, 862-868, 870-919, 921-945, 947-959, 962, 964-970, 972-976, 978-1021, 1023-1025, 1028-1034, 1037-1065, 1067-1088, 1090, 1093-1131, 1133-1154, 1157-1160, 1162-1165, 1167-1186
777F OEM	WTK00105-00117

PARTS NEEDED

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Qty	Part Number	Description
2	1W4795	NAMEPLATE-TURBO
2	5M6214	PLUG-PIPE
8	9X2201	CLAMP-BAND
4	2580817	HOSE
1	2663144	ADHESIVE
1	3300654	SOFTWARE GP-ELEK
1	ENINFOLAB	ENGINE INFORMATION LABEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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****Parts Stock ****

NOTE: 302-7438 and 302-7439 turbochargers in dealer parts stock that are intended to service serial number prefix 222, H4C, and LGK products do not need to be reworked.

Rework all 302-7438 and 302-7439 turbochargers in dealer parts stock that are intended to service 777F Off-highway trucks by using the section of the Rework Procedure that applies to the turbocharger.

****Affected Product****

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NOTE: PS42616 must be completed on the truck, when applicable, prior to performing this service letter.

NOTE: If the work was previously performed under PS42797, state in claim that this PI should not be performed. Also state in claim story that PS42797 was performed.

The engine software needs to be replaced and the wastegates need to be reworked on certain C32 engines installed in 777F Off-Highway Trucks. New Engine Specification Labels need to be ordered and installed as part of the updates.

NOTE: Perform this service procedure only for the machine serial numbers identified by this service letter. Permanently set turbo wastegate per the instructions in the service letter. Improper use of this part or service procedure may cause poor engine performance and may be prohibited by the clean air act and EPA regulations.

NOTE: A new Factory Password will need to be generated for the engine when performing the flash file update.

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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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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

NOTE: 0.5 Hours labor per turbocharger will be allowed to perform rework on turbochargers in dealer parts stock.

****Affected Product****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 2.0-hour job

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

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

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW ENGINE SOFTWARE AND REWORKING THE TURBOCHARGER WASTEGATES ON C32 ENGINES INSTALLED IN CERTAIN 777F OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 777F

Dear Caterpillar Product Owner:

The turbochargers need to be reworked on the products listed below. The existing turbocharger configuration can attribute to high exhaust temperatures. 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 25Nov2008 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 25Nov2008 Service Letter

Rework Procedure

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Inspect the 258-0817 Hose Assemblies circled below and make sure they are red in color. If the 258-0817 Hose Assemblies are not "Red" order new 258-0817 Hose Assembly from Caterpillar Parts Distribution and replace the hoses. Also, inspect the clamps used on those hose assemblies. If the hose assemblies are single clamped install a second 9X2201 clamp on each end.

Image1.1.1

Remove part number tags from Right Hand and Left Hand Turbo Chargers with appropriate tooling. Make sure both rivet heads are sheered off during removal. See Image 1.2.1 below for tag and rivet head location.

Image1.2.1

Stamp the new 1W4795 Turbocharger part number plates with new turbocharger part numbers listed below.
- Stamp 332-0045 for the Right Hand Turbocharger
- Stamp 332-0046 for the Left Hand Turbocharger

Clean part number tag area on turbochargers with emery cloth and 222-3117 Caterpillar Brake Cleaner.

Install new turbo part number tags using 5P3321 Caterpillar Epoxy Kit.
- One Epoxy Kit will service 5 engines.

NOTE: Only charge 1 Kit per 5 engines to this repair.
- Follow instructions on the Epoxy Kit and allow epoxy to harden before returning truck to service.

Image1.3.1

Remove fittings, hose, and clamp shown in Image 1.3.1 from the right hand turbocharger.
Remove the following:
(2) 2V4868 Fitting
(6) 161-6963 Clamp
(7) 242-3360 Hose
(4) 115-7087 Bolt
(5) 161-6958 Hose Clip
(8) 258-4524 Sleeve

Image1.4.1

Remove fittings, hose, and clamp shown in Image 1.4.1 from the left hand turbocharger.
Remove the following:
(2) 2V4868 Fitting
(6) 161-6963 Clamp
(7) 242-3360 Hose
(4) 115-7087 Bolt
(5) 161-6958 Hose Clip
(8) 258-4524 Sleeve

Install a 5M6214 Pipe Plug into the threaded holes in the compressor housing that had the 2V4868 Fitting and the 5P4536 Elbow installed in them.

Flash ECM with new 330-0654 engine software.

NOTE: New Factory Passwords will need to be generated.

Image1.6.1

Order and install new Engine Information Label.

NOTE: Label must be installed on engine prior to returning truck to service. Failure to do so could jeopardize the emissions/certifications compliance of the truck.

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

2. From the SIS web homepage, 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 Homepage.

7. Click on the emissions/certification replacement link.

Image1.7.1

8. Complete dealer name and address information.

Image1.8.1

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

10. Select certification label as the label type. Enter the number of this Priority 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.

Image1.9.1

Note: Be sure that the correct shipping information is provided. International requests must have a valid UPS or DHL account number.

NOTE: The Engine Information Label needs to be installed as directed in the rework procedure. If you do not receive the Engine Information Label contact: Global_Engine_Marking@cat.com.

11. Remove the original adhesive label and replace it with the new label and clear overlay.

12. If there are any questions regarding the adhesive label, contact Global_Engine_Marking@Cat.com

NOTE: A new test spec will be applicable to the engine after performing the turbocharger update. The new test specs (0K9609, 0K9610) are available in TMI. Determine which test spec is applicable to the engine before the turbocharger update by entering the engine or truck serial number in TMI.

Use the following reference to determine which test spec to use after the turbocharger update.

Before Rework_____After Rework
__0K5981_____________0K9609
__0K5982_____________0K9610