PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TURBOCHARGER HOUSINGS ON CERTAIN 3500 SERIES ENGINES. Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TURBOCHARGER HOUSINGS ON CERTAIN 3500 SERIES ENGINES.

Usage:

SEBE9018-02

January 3, 2005
(Revised June 2005)
U-1
A-1
D-1
O-1

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*Safety* *Parts stock action needed*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TURBOCHARGER HOUSINGS ON CERTAIN 3500 SERIES ENGINES.
1052		PI10333

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10333" 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 "PI10333" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the January 3, 2005 (Revised January 2005) Service Letter. Changes have been made to the Parts Needed and Problem Discription Sections.

PROBLEM

All Caterpillar turbochargers are designed and tested to ensure turbo wheel fragments do not exit the turbo housings should a turbo failure occur. Loose turbo parts exiting a turbo during a turbo failure present a potential safety hazard. Recent tests have indicated the 1135181, 1989916, and reman 0R7719 turbos on the above engines can fail to contain some loose turbo fragments should a turbo failure occur. NOTE: This service letter is issued to address a hardness problem with the housing. Other types of turbo damage are not covered in this service letter.

AFFECTED PRODUCT

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Model

Identification Number

3512B

6GW141, 147, 192, 195, 202-203, 214, 219, 243, 317-318, 353-354, 395, 397, 400-403, 647, 660-661, 667, 693-694, 725, 740-743, 753-754, 761-764, 766, 831, 835-836, 838-839,844-847, 853, 1042

6WN76-98, 102-112, 116-117, 121-125, 127-132, 134-140, 142-150, 152, 154, 159, 161-167, 169-186, 189-197, 199-210, 212, 214-254, 256-263, 265-277, 279-292, 294-387, 391-411, 413-432, 435-449, 451, 453, 455-464, 467-543, 545, 547, 549-561, 563-586, 589-608, 611-712, 715-738, 740-802

8RM1, 107, 109-112, 130-131, 138-140, 148-150, 153-154, 156-158, 175, 189-190, 199-200, 203-208, 211, 217-218, 220-221, 235-237, 240-243, 251-252, 254, 262, 272-274, 277, 279, 284-285, 291-292, 294, 296, 302, 306, 309, 311-314, 316-317, 321-322, 324, 326-330, 333-334, 337, 339-341, 347, 349-350, 352-354, 360, 366-367, 371-385, 393-394, 397-398, 401-408, 410-431, 433-436, 438, 440, 442-452, 456-459, 462-464, 469, 471, 474-475, 481, 491-492, 499, 501, 504, 507, 509, 513-514, 517, 519-522, 526, 529, 533, 535, 538-541, 544, 546, 548-549, 553-554, 556, 565, 569-570, 578, 583, 586-587, 597, 599, 606, 608, 612, 614, 624-625, 630, 632, 636-638, 653, 656-657, 659, 661-662, 665, 667, 669, 671-672, 675-678, 680-692, 694-695, 697, 699-701, 704, 709-710, 712-713, 717, 731-732, 735-740, 749, 754, 757, 759

BNR311-313

CMC112-113, 115-117, 121, 124-126, 128-139, 141-145, 147-149, 152-154, 158, 161-162, 164, 173, 177, 179-185, 187-188, 190-193, 198-205, 208-210, 212-222, 224, 226-228, 231, 234, 237-240, 242-243, 246-263, 267-277, 283, 286-287, 296-301, 303-304, 306-311, 320, 322, 325-327, 332-336, 340-345, 348-360, 362-367, 369, 372-378, 390-391, 394-395, 397-404, 406, 410-411, 413-414, 416-418, 420-424, 439-440, 442, 448, 450-451, 453-459, 463, 465-467, 469-475, 480-485, 487, 489-492, 494, 499, 501-503, 512-513, 515-516, 520, 527-529, 531-538, 540-541, 544-554, 556, 561-568, 573-580, 582-586, 588-589, 591-594, 596-626, 629-633, 637-642, 644, 646-651, 658, 661, 663-665, 667-678, 680-682, 684-685, 687-688, 691-692, 694, 697-703, 707-717, 719-720, 729-735, 741, 743-747, 751-758, 760, 762-764, 767-775, 777-780, 782-783, 786-790, 792-804, 808-810, 813-823, 825-827, 837-839, 843-854, 860, 869-870, 872-873, 876-877, 880-884, 887, 890, 892-893, 895-899, 908-912, 923-927, 931-935, 944, 950-953, 955-959, 964, 968-974, 979, 982, 989-997, 1002-1005, 1010, 1015-1016, 1020-1022, 1025-1026, 1028-1029, 1036-1041, 1044-1046, 1056-1058, 1064-1066, 1071-1076, 1080-1081, 1086, 1088-1089, 1095-1096, 1098-1105

PARTS NEEDED

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Qty	Part Number	Description
1	2631452	TURBO-KIT

NOTE: There are 4 turbine housings per kit. Only 1 kit is required per engine.

ACTION REQUIRED

***** Parts Stock *****

Rework all 1135181, 1989916, and 0R7719 TURBO GROUPS in parts stock.

In order to remove a turbine housing from an existing turbocharger, place the turbocharger compressor side down and follow steps 3 through 7 in the "affected product" section below. Make sure the turbo impellers spin freely.

After the rework has been completed use a 1/8" stamp to stamp a "W" on the end of the turbocharger part number. The nameplate is located on the turbocharger cartridge as shown below:

Please keep in mind this stamping method is only for the turbocharger part numbers listed above.

***** Affected Product *****

Follow the removal procedure within publication "Turbocharger - Remove - Center Mounted Turbocharger", SENR6564 to remove the turbocharger from the engine.
After the turbocharger is removed, place the turbocharger on a bench top with the compressor side down.
Loosen the turbine housing band clamp.
Carefully lift the turbine housing from the turbo.
Install the new turbine housing.
Carefully install the band clamp.
Tighten the band clamp, but leave it loose enough to turn the housing.
Install turbo on exhaust manifold and tighten bolts to 55 newton-meters.
Be sure to apply anti-seize to bolts.
Tighten the oil supply line, the turbo drain, and the compressor housing to the after-cooler to 47 newton-meters.
Then tighten band clamp on turbine housing to 14 newton-meters and tap on band clamp.
Then retighten to 14 newton-meters.
Make sure turbo impellers spin freely.
Install air intake tube and tighten hardware.

After the rework has been completed use a 1/8" stamp to stamp a "W" on the end of the turbocharger part number. The nameplate is located on the turbocharger cartridge as shown below:

Please keep in mind this stamping method is only for the turbochargers shown below effected by this rework.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

***** Parts Stock *****

Submit one claim for all TURBO GROUPS reworked in parts stock.

***** Affected Product *****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	6.0	0	0	0	0
NOTE: This is a 6.0 - hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

***** Parts Stock *****

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

***** Affected Product *****

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TURBOCHARGER HOUSINGS

MODELS INVOLVED - CERTAIN 3500 SERIES ENGINES.

Dear Caterpillar Product Owner:

A new turbo housing needs to be installed on the products listed below. Loose turbo parts exiting a turbo during a turbo failure could cause injury or death. 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 January 3, 2005 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to January 3, 2005 Service Letter