PRODUCT SUPPORT PROGRAM FOR REPLACING TURBOCHARGERS ON CERTAIN 3500 SERIES ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING TURBOCHARGERS ON CERTAIN 3500 SERIES ENGINES

Usage:

SEBE9430

December 13, 2005
U-392
A-291
D-308
O-328

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*Before or* *after failure* *Parts stock action needed*	PRODUCT SUPPORT PROGRAM FOR REPLACING TURBOCHARGERS ON CERTAIN 3500 SERIES ENGINES
1052		PS41938

NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS41938" 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.

NOTE: Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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.

TERMINATION DATE

December 13, 2007

PROBLEM

The 2454339/">245-4339 turbo is failing during commissioning, at very early hour, at multiple sites. Preliminary inspection of failed turbochargers indicates the turbochargers are experiencing over speed / over temp for the compressor wheel causing the compressor wheel to become unbalanced, rub then fail. In addition the turbo manufacture is having problems with the balancing of the turbo rotating assembly. Turbo manufacturer reviewed their balancing process and noted a change that took place during a period of operation that also coincides with the date codes on the failed turbochargers.

AFFECTED PRODUCT

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Model	Identification Number
3508B	5PS331 CNB1052, 1055-1059, 1061, 1066-1069, 1072, 1074-1075, 1081, 1084, 1087, 1092, 1095-1099, 1101-1102, 1105-1106, 1108-1125, 1127-1132, 1135-1145, 1149, 1153-1157, 1159, 1161-1192, 1195-1202, 1206-1227, 1230-1231, 1235-1237, 1239-1240, 1242-1252, 1254, 1256, 1258-1260, 1263-1266, 1270-1272, 1277-1293, 1295, 1298, 1300-1314, 1317-1318, 1321-1328, 1330-1334, 1340-1341, 1347-1348, 1360-1364, 1372-1373, 1376-1380, 1382-1387, 1391, 1393-1395, 1399-1411, 1415, 1421, 1424-1433, 1435-1437, 1440-1445, 1447, 1454-1455, 1458, 1460, 1465, 1480-1492, 1494, 1496-1498
3516B	2JW415-418 7RN1960-1961, 1963-1964, 1966, 1970-1973 BPJ457-497 FDN1475-1500, 1502-1504, 1508-1513, 1515-1520, 1522-1525, 1528, 1531, 1534-1535, 1539-1541, 1543-1668, 1670-1679, 1681-1684, 1699-1730, 1735-1783 FDX235, 251, 253-261, 264-269, 272-280 GAR111-136, 138, 140-144 ZAP114
G3516B	GZS111-151, 153-168, 170-171, 173-238, 240-241, 246-251, 259, 267-268, 270, 274, 276-279, 283-287, 289-290
PP3516	PPS156

PARTS NEEDED

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Qty	Part Number	Description
*	2454339	TURBO GP-BAS

*NOTE: Order only the number needed after the inspection has been completed.

ACTION REQUIRED

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

Remove all 2454339 Turbochargers from parts stock.

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

Inspection:

Illustration 1

Listing of suspect turbo serial numbers:

Turbocharger replacement:

Group 1- For 3508s

Follow the removal procedure within publication "Turbocharger - Remove ? Rear Mounted Turbocharger", SENR6564 to remove the turbocharger from the engine.
After the turbocharger is removed, replace the turbocharger using publication "Turbocharger - Install ? Rear Mounted Turbocharger", SENR6564.

Group 2- For 3516s

Follow the removal procedure within publication "Turbocharger - Remove ? Center Mounted Turbocharger", SENR6564 to remove the turbocharger from the engine.
After the turbocharger is removed, replace the turbocharger using publication "Turbocharger - Install ? Center Mounted Turbocharger", SENR6564.

SERVICE CLAIM ALLOWANCES

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

Submit one claim for all 2454339 Turbochargers that are removed from parts stock.

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

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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
0-100	100%	2.0*	0	0	0	0
*NOTE: This is a 2.0 hr job for each turbocharger replaced. A maximum of 4 turbochargers can be replaced. NOTE: An additional 0.5 hrs will be allowed for inspection per engine. NOTE: Travel time and mileage will be allowed on this product support program.

PARTS DISPOSITION

NOTE: All dealers are to make sure the outside of the shipping container is marked with the service letter number. ***** U.S. and Canadian Dealers *****

Return all 2454339 Turbochargers that are removed from parts stock and a copy of the claim to:

Caterpillar Inc.
Attn: Supplier Recovery
Service Claims Room
8201 N. University
Peoria, IL 61615

***** All Other Dealers *****

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