TERMINATION DATE

PROBLEM

AFFECTED PRODUCT

PARTS NEEDED

ACTION REQUIRED

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first

Parts

When claiming for this service letter, use the following SMCS codes and times:

PARTS DISPOSITION

Attach. (1-Rework Procedure)
        (2-Dealer Feedback Form)

1. Have a print out of the Dealer Feedback Form ready to complete prior to starting the procedure.
2. Flash unit with February release software. See chart above for proper file.
1. Connect Caterpillar Electronic Technician to the engine and flash the ECM with February 2004 release parts service software.
3. Replace pre-cooler hoses

 

 
 
 

NOTE: This step is ONLY required IF the unit being inspected falls within the following ranges: KCA161-731, KCB508-3228.

1. Replace the water inlet and water outlet hoses on the pre-cooler. Reference Figures 1-3 below.
2. For LOW MOUNT TURBOCHARGERS (Illustration 1), use:
1. 2398139 Hose ? water inlet
2. 2398142 Hose ? water outlet


Illustration 1

3. For MID MOUNT TURBOCHARGERS (Illustration 2), use:
1. 2398141 Hose ? water inlet
2. 2398143 Hose ? water outlet


Illustration 2

4. For HIGH MOUNT TURBOCHARGERS (Illustration 3), use:
1. 2398140 Hose ? water inlet
2. 2398144 Hose ? water outlet


Illustration 3

4. Inspect air compressor check valve expansion chamber (air box), and clean if necessary. See Figure 4 below.

 

 
 
 

NOTE: This step is ONLY required IF the unit being inspected falls within the following ranges: KCA161-731, KCB508-3228.

NOTE: Failure to perform this procedure may result in an air compressor failure.

1. The tank assembly may contain certain types of debris that could damage the air compressor. Examples of debris may include weld berries, MIG welding wire, etc. To inspect the air compressor check valve air box, perform the following steps:
1. Remove the tank from the engine
2. Inspect hose and tubing for debris, and clean as necessary
3. Remove the reed valve cover plate from the tank, and ensure the reed valve cover plate gasket is not damaged.
1. If the reed valve cover plate gasket IS damaged, replace it with another 2405882 Gasket.
2. If the reed valve cover plate gasket IS NOT damaged, reuse it
4. Inspect, and clean the inside of the tank.
1. Chase a tap, bolt or fitting through all threaded bosses at least twice to free up any machining debris, and blue loctite.
2. Using emery cloth, dislodge any remaining debris on the inside of the air box and around the threaded bosses.
3. Use a screwdriver, metal chisel, or magnet to remove any remaining debris.
4. Blow out air box using compressed air.
5. Clean the inside of the air box with an oily cloth or shop towel.
6. Reassemble with loctite product number 242 (reference CAT part number 4C4030) on reed valve cover plate bolts.


Illustration 4

5. Inspect high-pressure turbocharger mounting nuts.
1. The high-pressure turbocharger to exhaust manifold studs and nuts must have the torque validated. See Illustration 5 below.
1. Validate the torque for the turbocharger to exhaust manifold nuts.
2. Proper torque is 70 Nm (52 lbft)


Illustration 5

6. Inspect air-ducting
1. Inspect all inter-stage ducting of the turbocharger system.
1. Bellows piping should be properly aligned with no signs of cracking.
2. V-band clamps must be tight.
1. Bellows to duct V-band clamps should be tightened to 7 N.m +/- 2N.m. See Illustration 6 below.



Illustration 6
2. Duct to turbocharger V-band clamps should be tightened to 12 N.m +/- 2 N.m. See Illustration 7 below.
3. For both turbocharger housing V-band clamps, reference Illustration 7 & 8 below, and perform the following:
1. Validate torque is 14 N.m
1. If torque is below 14 N.m then also perform the following:
1. Tighten to 18 N.m
2. Loosen to 6 N.m
3. Retighten to 14 N.m


Illustration 7

7. Inspect Turbocharger
1. Validate the torque of the 12-point bolts in the LOW-PRESSURE turbocharger housing. See Illustration 8 below.
2. The proper torque value for these bolts is (20.9 ? 24.3 N.m).
3. If the mechanic finds that any of the bolts are missing, call the following phone number: (309) 578-6149 and request that the required number of bolts be mailed.
4. The following information will be required prior to shipment:
1. Serial Number
2. Mileage
3. Address with name of contact


Illustration 8

8. Other general inspections:
1. Mounting hardware
1. Check for loose bolts and mounting hardware throughout the engine. Only re-torque bolts that are found to be loose or missing. Refer to the torque specifications guide for proper torque values on all bolts.
2. Oil system
1. Visually inspect engine for any oil leaks. At the minimum, check the following areas: Front cover, power steering pump mounting, oil pan, turbo supply and drain lines, oil cooler. If a leak is found, determine the source of the leak and repair.
3. Cooling system
1. Inspect for any coolant leaks.
4. Electrical system
1. Check all electrical components for corrosion, or abrasion, as well as proper connection.
5. Fuel system
1. Inspect all hoses. Make sure fittings are tight and not leaking.
2. Check fuel filter base and hand priming pump for signs of leaks.

Dealer Feedback Form

PLEASE FAX RESULTS TO THIS NUMBER:

(309) 578-2673

Dealer Feedback Form

ATTN: PS41544

1) Fill out the following information:

Engine S/N: __________

Engine Mileage: __________

Engine TOTAL Hours: __________

Dealer Code: __________

          2) Engine was flashed with February release software?

4) Did the mechanic find any debris in the air compressor check valve expansion chamber (KCA00161-00731 and KCB00508-03228 only)? ðYes ðNo

If yes, describe type of debris

          6) Were all the bellows pipes tight, aligned, and crack free?

       ð Yes ðNo

a. If not, indicate by the numbers in Figure 6 which clamps were loose? _____

          7) Were all turbocharger V-band clamps, and housing bolts tight? ðYes ðNo

a. If not, indicate by the numbers in Figures 7 & 8, which CLAMPS were loose? _____

 

          8) Were there any other issues discovered during the general inspection? ðYes ðNo