Product Support Program For Adding Enhancements To Improve Engine Response On Certain 836 Compactors Caterpillar

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.

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 "PS8971" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Termination Date

Problem

An Enhancement Kit needs to be added to improve engine response on certain 836 Compactors. This engine kit provides parts and instructions on how to update the current field population of machines equipped with the 3408E Engine.

NOTE: This will increase the heat loads on the cooling system of the older machines. It is recommended that PS8970 and PS8906 be performed at the same time as this program.

Affected Product
Model & Identification Number

836 (7FR1-263)

Parts Needed

1 - 1445328 Kit - Performance

Action Required

See the attached Rework Procedure.

Service Claim Allowances

NOTE: This is a 4-hour job.

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

Special Tool Required: 9S9082 Pinion Tool

SEHS9343 Special Instructions.

Centrifugal Valve Installation:

1. Remove 5D6535 Cover from the rear of the 2P5806 Torque Converter Housing.

2. Using 9S9082 Engine Turning Tool, to rotate flywheel and torque converter rotating housing until 6P8921 Cover is in full view of the opening in the turbocharger housing.

3. Carefully remove 6P8921 Cover, 6P0383, 2P5808 and 2P5809 Shims, and 4 - 1T0414 Bolts and 9M1974 Washers.

NOTE: Do not drop any of the bolts or washers into the turbocharger housing.

4. Install the 1430912 Centrifugal Valve Group using 6P0383, 2P5808 and 2P5809 Shims (as required) and 4 - 1T0414 Bolts and 9M1974 Washers.

5. Reinstall the 5D6536 Cover and new 4D8621 Gasket using 4 - 9M1974 Washers and 1T0414 Bolts. Tighten to 30 N·m.

Turbo Removal:

1. Disconnect turbocharger oil supply 1271967 Tube Assembly at the adapter on the engine block and plug all openings immediately.

2. Remove the 0S0509 Bolt and 5M2894 Washer that hold tube clamp to engine block.

3. Remove 2 - 0S1571 Bolts, 1271967 Tube Assembly and 6J2245 Seal from Turbocharger.

4. Remove 2 - 1A2029 Bolts and 5M2894 Washer that hold drain tube, 1271968 Tube Assembly and 5P7530 Seal from the bottom of the Turbocharger.

5. Loosen 5P3860 Clamp in 1229199 Lines Group and disconnect 1229196 Elbow from the inlet side of the turbocharger assembly.

6. Remove the 4 - 2N2765 Bolts and 2N2766 Lock Nut that hold the turbocharger group to the mounting flange.

7. With a suitable lifting device remove the turbocharger from the mounting surface.

8. Remove the turbocharger 1S4295 Gasket.

Turbo Installation

1. Check all O-Ring seals for wear or damage before reusing them. Replace them with new parts if necessary.

2. Install a new 1S4295 Gasket and 1279177 Turbocharger. Position the turbocharger cartridge and housings with air pipes, exhaust pipes and oil lines to they are all aligned and without binding.

3. Apply 5P3931 Anti-Seize Compound to the threads of the mounting bolts. Install turbocharger mounting 1T0414 Bolts and 2N2766 Nuts (finger tighten only).

4. Position turbocharger oil drain line 1271968 Tube Assembly and seal in its original location and install 2 - 1A2029 Bolts and 5M2894 Washer. Finger tighten only.

5. Position turbocharger oil inlet line 1271967 Tube Assembly and seal in its original location and install 2 - 0S0509 Bolts and 5M2894 Washer.Finger tighten only.

6. Reinstall 0S0509 Bolt and 5M2894 Washer that hold tube clamp to engine block. Finger tighten only.

7. Reconnect turbocharger oil supply 1271967 Tube Assembly at the adapter on the engine block.

8. After all components are positioned and aligned without binding, tighten the turbocharger V-Band clamp nuts. Tighten to 14 N·m.

9. Tap the V-Band clamps lightly all around, and torque the nuts again. Tighten to 14 N·m.

10. Tighten turbocharger mounting 1T0414 Bolts and 2N2766 Nuts. Tighten to 55 N·m.

11. Tighten turbocharger oil drain line mounting 1A2029 Bolts and 5M2894 Washer. Tighten to 47 N·m.

12. Tighten turbocharger oil inlet line mounting 0S0509 Bolts and 5M2894 Washer. Tighten to 47 N·m.

13. Reinstall 0S0509 Bolt and 5M2894 Washer that hold tube clamp to engine block. Tighten to 47 N·m.

Engine Rerate Procedure

Part of the engine rerate for the 836 involves installing a new personality module and a new engine information plate. The following procedure must be followed when performing this rework.

NOTE: Use caution when removing the fuel lines.The fuel may be under pressure and can penetrate body tissue.

1. Connect ET using the Communication Adapter Tool to access Parameters from the Electronic Control Module (ECM) being replaced.

2. Record the Parameters listed.

NOTE: If the Parameters cannot be read, they must be obtained elsewhere. Some parameters may be stamped on the Engine Information Plate, but most parameters must be obtained from the dealer.

Moisture entry into the ECM from improper servicing will result in ECM failures.

Improper O-Ring placement could result in moisture damage caused by improper sealing.

Do NOT over tighten bolts. This could result in damaged threads and moisture damage from improper sealing.

Do NOT lose any of the ECM mounting hardware (i.e. rubber grommets, spacers and washers).

3. Turn the key switch to the OFF position.

4. Use a 4 mm allen wrench to disconnect both 40 Pin Deutsch connectors.

5. Disconnect the two fuels lines attached to the ECM and plug all openings immediately.

6. Remove the 3 - 8H8769 Bolts, 1 - 3H5932 Bolt, 5 - 9N0869 Washers, 9M1974 Washer, 8 - 8T9655 Rubber Mounts, 4 - 1156469 Spacers, and ECM from engine.

7. Remove the tag wire and 4 - 3E6900 Bolts, 3E6299 Cover and 6V1179 Seal from the back side of the ECM.

NOTE: Do NOT remove the cover from the TOP of the ECM that is located under the wiring harness 40-Pin Connectors.

8. Remove the Personality Module by squeezing the tabs on the ends of the blue plastic and pulling the module straight out of the ECM.

9. Install the new 1437938 Personality Module, making sure that it seats properly into the Personality Module Socket (blue EPROM carrier socket). The socket is keyed to accept the Personality Module in one position only. A click can be heard when the new Personality Module is installed properly.

NOTE: DO NOT use excessive force to push the module into the socket.

10. Check the 6V1179 Seal for wear or damage and position the O-ring seal. Replace the Seal with a new seal if required.

11. Install 3E6299 Cover and secure with 4 - 3E6900 Bolts. Tighten to 21.36 N·m or 12.

NOTE: Ensure that the O-ring seal is seated properly.

12. Install locking wire and governor seal.

13. Mount the ECM on the engine using the old hardware. (3 - 8H8769 Bolts, 1 - 3H5932 Bolt, 5 - 9N0869 Washers, 9M1974 Washer, 8 - 8T9655 Rubber Mounts, 4 - 1156469 Spacers, Ground Wire and ECM to engine.) Tighten to 25 N·m.

14. Reconnect the two fuels lines to the ECM.

15. Use a 4 mm allen wrench to reconnect both 40 Pin Deutsch connectors.

16. Connect the ET Service Tool to the machine.

17. Turn the Key Switch to the 'ON' position for 30 seconds, but do not attempt to start the engine.

NOTE: ET (version 1.6 required) will generate fault "253-02" (Personality Module Mismatch) due to the new personality module when power is supplied to the ECM. You can not start the engine until you obtain a factory password to clear the interlock fault.

18. Obtain a factory password to clear the interlock fault and allow operation of the engine. Passwords may be obtained at the dealership or by calling 1-800-447-4986.

19. Follow the special instructions provided in SEHS9343 for reprogramming the interlock using the ET.

After rerating the engine, the Engine Information Plate must be replaced to maintain Environmental Certification.

20. The 1210173 Information Plate must be stamped and applied to the valve cover. All information which is unchanged (i.e., Serial Number, Engine Model, etc.) will have to be stamped on the new plate as well as the rerated information. The rerated information can be determined from the Caterpillar Technical Marketing Information System (TMI - see "Procedure to Find Information to Rerate") Prior to accessing this information, it will be necessary to obtain the engine serial number from the Engine Serial Number Plate located on the engine.

21. Stamp the new plate using 3 mm maximum block figures. Flatten the plate after stamping. Install the new plate in place of the original information plate or decal. Completely clean the area where the new plate is to be installed. Use Adhesive 8T9021 to install the new plate.

Illustration 1

Illustration 2

Illustration 3

Illustration 4