PRODUCT SUPPORT PROGRAM FOR REMOVING THE PAINT FROM THE EXHAUST MANIFOLD AND/OR TURBO ON CERTAIN INDUSTRIAL ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REMOVING THE PAINT FROM THE EXHAUST MANIFOLD AND/OR TURBO ON CERTAIN INDUSTRIAL ENGINES

Usage:

REBE2464-01

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05Sep2007

(Revised 03Sep2008)

K260
T080
Q311
J080
M450
V563
V434
R440
L310
M530
M189
L395
L050
V218
Q633
V462
K624
M180
M410
V470
U062
J040
T030
L145
J490
N050
J250
M670
K550
V35A
K680
N020
T120
M680
M638
J421
J500
X49B
J090
X190
M182
K313

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REMOVING THE PAINT FROM THE EXHAUST MANIFOLD AND/OR TURBO ON CERTAIN INDUSTRIAL ENGINES
1059 1052		PS42500

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NOTE:

This Program must 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 "PS42500" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 05Sep2007 Service Letter. Changes have been made to Affected Product and Termination Date.

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TERMINATION DATE

30Sep2009

PROBLEM

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The exhaust manifold and/or turbo on certain industrial engines has unacceptable levels of paint. This paint needs to be removed to conform with local regulations.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C11	GLS01340, 1343-1344, 1346, 1376, 1383-1384, 1387-1388, 1392, 1395, 1415-1419, 1432-1434, 1437, 1440, 1444-1445, 1471, 1473-1474, 1476-1477, 1489, 1494-1495, 1511, 1534, 1580-1584

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*****Group 2*****
C13	LGK06585, 6589-6590, 6630, 6858-6860, 6890, 6892, 6894, 6927-6928, 6930, 6961, 6990, 7009-7010, 7013-7015, 7018, 7020-7021, 7041, 7057-7060, 7062-7063, 7265, 7267-7268, 7270-7271, 7313, 7327-7328, 7338, 7352, 7356, 7365, 7368, 7387-7388, 7408, 7410, 7414-7415, 7448, 7459-7460, 7487-7491, 7498, 7501-7502, 7512-7514, 7518, 7534, 7562, 7583, 7585, 7595, 7621, 7624-7625, 7636, 7643-7645, 7671

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*****Group 3*****
C15	JRE04733, 4795, 4815, 4838, 4947, 4956, 4995, 5229, 5231-5232, 5334-5335

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*******Group 4*******

JTF02079, 2082, 2084, 2087, 2145-2149, 2151-2156, 2158, 2160-2161, 2195, 2205-2206, 2211-2212, 2228-2232, 2234, 2240, 2244, 2259-2261, 2263, 2265-2267, 2271, 2286-2290, 2301-2303, 2305-2306, 2352-2354, 2356, 2358-2359, 2481, 2490, 2492, 2496, 2498-2499, 2503, 2505, 2509, 2512, 2515, 2517, 2519-2520, 2537-2541, 2543, 2549-2552, 2561, 2565, 2570-2572, 2574-2575, 2577-2578, 2580-2582, 2598, 2651, 2653-2656, 4792-4796, 4866, 4868, 4870-4871, 4873-4875, 4878, 4883-4884, 4891-4893, 4897-4900, 4904, 4911, 4914, 4916, 4919-4920, 4923, 4936-4938, 4940-4941, 4943-4944, 4970, 5119, 5122-5123, 5126, 5128, 5141, 5143, 5146-5148, 5266-5267, 5270, 5272, 5282, 5299, 5302-5305, 5316, 5318, 5321, 5327-5329, 5332-5334, 5336, 5344, 5347, 5351-5352, 5356, 5359-5361, 5366-5367, 5371-5372, 5378, 5381-5385, 5388, 5390, 5395, 5400, 5405, 5413-5414, 5424-5425, 5428, 5436-5437, 5447-5449, 5459, 5473, 5483-5485, 5495, 5497, 5690, 5692-5695, 5707-5711

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
12	3E8017	LOCKNUT
1	0336033	SEAL-O-RING
1	1978418	GASKET
1	1978419	GASKET
1	2256948	SEAL-O-RING
6	2832238	GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
12	3E8017	LOCKNUT
1	0336033	SEAL-O-RING
1	1978418	GASKET
1	1978419	GASKET
1	2256948	SEAL-O-RING
6	2832238	GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 3*****
1	2M9780	SEAL-O-RING
12	2N2766	LOCKNUT
1	1142687	SEAL-O-RING
1	1262702	SEAL-INTEGRAL
6	1299452	GASKET-EXH MANF
1	1986068	SEAL-INTEGRAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 4*****
2	3P1156	SEAL-O-RING
1	2147568	SEAL-O-RING-STOR
1	2213494	SEAL-O-RING
6	2721956	GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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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%
*****Group 1*****
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 1

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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%
*****Group 2*****
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 2

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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%
*****Group 3*****
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 3

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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%
*****Group 4*****
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 4

PARTS DISPOSITION

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

Rework Procedure

1. Remove turbo oil supply line and Turbo oil drain line. See Image 1.1.1.

NOTE: Lines configuration may be different for different engine models.

Image1.1.1

2. Remove exhaust manifold and turbocharger from the cylinder head. The turbocharger should remain attached to the exhaust manifold.

3. Remove the turbo cartridge and compressor housing as one unit. This can be done by removing the clamp that holds the center section to the turbine housing. Take extra caution to not damage the turbine wheel when removing cartridge from the turbine housing. See image 1.3.1 and 1.3.2.

Image1.3.1

Image1.3.2

4. Cover all open ports on the exhaust manifold and turbine housing before beginning the cleaning process to reduce the opportunity for contamination. This will also protect vital surfaces from being damaged during cleaning.

5. Use approved cleaning processes to remove paint from exhaust manifold and turbine housing. Refer to SEBF8360 for a flow chart on correct method for cleaning exhaust system components.

6. It is recommended that a sand or metallic based material not be used in blasting type systems. This is to prevent contamination from entering the components being cleaned that could harm the engine or turbocharger once this procedure is completed.

7. Re-install turbo cartridge and compressor housing into the turbine housing. Take extra caution to not damage the turbine wheel fins when inserting the cartridge into the turbine housing. Refer to the specifications section in SIS web for correct tightening procedure of the band clamp.

8. Re-install the exhaust manifold/turbocharger. New gaskets and fasteners should be used. Refer to the specifications section in SIS web for correct tightening procedure of the exhaust manifold.

9. Re-install turbo oil supply and drain lines. Make sure new gaskets and/or seals are used.