PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER ON CERTAIN C-12 TRUCK ENGINES

Usage:

SEBE8471-02

August 14, 2003
(Revised January 2004)
U-218
A-155
D-159
O-178
TT-20

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER ON CERTAIN C-12 TRUCK ENGINES
1052		PS50721

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 "PS50721" 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.

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 Revised Service Letter replaces the August 14, 2003 (Revised October 2003) Service Letter. Changes have been made to the Service Claim Allowances.

TERMINATION DATE

August 31, 2005

PROBLEM

The turbochargers may fail on certain C-12 truck engines with through bore compressor wheels, due to compressor wheel burst. The turbocharger needs to be replaced.

AFFECTED PRODUCT

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Model	Identification Number
C-12	2KS1-53840 9NS1-Up

Use the following chart to determine which turbocharger to use for the unit being repaired:

PART NUMBER REFERENCE FOR TURBOCHARGER REPLACEMENT

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New Turbo Part Number (for reference)	Reman Turbo Part Number
1906204	0R7574
1906205, 1906206	0R7575
1906207, 1906208	0R7576
1906210, 1906211	0R7578
1906212, 1906213	0R7579

For ALL repairs, replace the following gaskets:

PARTS NEEDED

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Qty	Part Number	Description
1	1S4295	MANIFOLD GASKET
1	8H9788	SUPPLY LINE GASKET
1	1886126	DRAIN LINE GASKET

ACTION REQUIRED

See the attached Rework Procedure.

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
0-300,000 mi 0-8000 hrs	70%	4.7	0	0	30%	0
300,001-400,000 mi 8001-10,000 hrs	50%	2.4	0	0	50%	2.3
400,001-500,000 mi 10,001-12,000 hrs	30%	1.4	0	0	70%	3.3
500,001-Up mi Over 12,000 hrs	0%	0	0	0	100%	4.7
NOTE: This is a 4.7?hr job.

LABOR

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SMCS Code	Name	Time Allowed
1051-010	Air filter housing remove and install (in frame)	0.5
1052-010	Turbocharger remove and install (in frame)	1.3-1.6
1052-017	Turbocharger disassemble and assemble	0.5
1052-040	Turbocharger inspect (in frame)	0.2
1064-010	R&I ATAAC core	0.9
1064-046	Flush ATAAC core	1.0

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

NOTE: Only turbochargers with the through-bore design are covered under this service letter.

Confirm the turbocharger has a through bore design turbocharger compressor wheel. Refer to the pictures, and charts below to help make this determination.

Illustration 1

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Style	Visual Characteristics	Turbocharger Part Numbers
Through Bore Wheel	End of shaft is visible in the nose of the wheel	1309201, 1513082, 1515937, 1626495, 1627603, 1649490, 1649493, 1649496, 1275793, 1378928, 0R7084, 0R7252, 0R7289, 0R7292, 0R7293, 0R7055, 0R7175
Boreless Wheel	Only has a dimple on the nose of the wheel	1906204, 1906205, 1906206, 1906207, 1906208, 1906210, 1906212, 1906213, 1906221, 1906222, 0R7574, 0R7575, 0R7576, 0R7578, 0R7579, 0R7580, 0R7581

If your turbocharger has the Through Bore Wheel, and you fall within the affected SN range(s), proceed with replacement of the turbocharger if the failure mode is a compressor wheel burst.

NOTE: There are pictures below to help show what this failure mode looks like.

C12 Compressor Wheel Burst

The compressor wheel is split through the center. (Illustration 2)
On through bore style wheels the split will be through the center hole.
If the wheel is missing, look on the underside of the compressor cover. A wheel burst has happened if there are deep impact marks 180 degrees apart. (Illustration 2)