PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST RISERS ON CERTAIN C32 ENGINES
Usage:
REBE3258-00
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| 25Mar2008 |
U-148
A-116
D-110
O-132
TM-10
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| After Failure Only | PRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST RISERS ON CERTAIN C32 ENGINES |
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| 1059 | PS51462 |
|
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| 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 "PS51462" 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. |
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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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TERMINATION DATE |
| 31Mar2010 |
PROBLEM
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| The 4P-8251 and 4P-8252 Water-cooled Exhaust Risers, within the 4P-7478 Exhaust Manifold group, may fail where the integral 90 deg bracket is welded to the riser. Typically, this weld failure results in loss of coolant. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| C32 | RXB02473, 2479, 2550, 2553, 2578, 2581, 2596-2597, 2600, 2603, 2740-2742, 2744-2746, 2751-2753, 2775, 2784, 2910, 2912, 2915-2916, 2923-2930, 3014-3015, 3017-3022, 3042, 3044-3045, 3074, 3093, 3112, 3120-3121, 3134, 3136, 3140-3150, 3164-3174, 3205-3208, 3264, 3268-3269, 3271-3272, 3274-3275, 3277, 3288, 3291-3293, 3322-3323, 3326-3329, 3331, 3334, 3336-3337, 3339-3340, 3344, 3478, 3489, 3506, 3512, 3516 |
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| *******Group 2******* | |
| C32 | RXB00246, 256, 277, 279, 309-311, 320-323, 348-351, 356-359, 2187, 2191, 2193-2195, 2202, 2204, 2216-2217, 2220-2223, 2251-2255, 2257, 2274, 2291-2294, 2297, 2300, 2310-2311, 2323-2324, 2332, 2355, 2365-2369, 2371-2375, 2379-2380, 2382, 2405, 2407, 2411-2417, 2459, 2461, 2463-2464, 2467, 2486-2489, 2497, 2500-2502, 2504, 2516, 2519, 2538, 2541, 2543-2544, 2583, 2589, 2604-2605, 2617-2618, 2629, 2637, 2639, 2641-2642, 2652, 2673, 2675, 2685, 2687, 2701-2702, 2704, 2728-2730, 2732, 2734, 2736, 2738-2739, 2743, 2747-2750, 2754-2757, 2760, 2762, 2764, 2771, 2773, 2786-2787, 2829, 2839, 2842, 2896, 2911, 2914, 2948, 2951-2952, 2954-2955, 2980, 3023-3024, 3031-3032, 3046-3048, 3079-3084, 3100, 3106, 3110-3111, 3131, 3133, 3135, 3152, 3179-3180, 3188-3190, 3193, 3211, 3225, 3227, 3276, 3300, 3305, 3308, 3315, 3351, 3353, 3442, 3444, 3446, 3491, 3526, 3548, 3587, 3589, 3593-3594, 3598 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 6 | 0L2070 | BOLT (IF NEEDED **) |
| 4 | 0S1591 | BOLT (IF NEEDED **) |
| 1 | 0S1594 | BOLT (IF NEEDED **) |
| 1 | 2A4639 | BOLT (IF NEEDED **) |
| 2 | 2Y9255 | SPACER (IF NEEDED **) |
| 1 | 4W9149 | SPACER (IF NEEDED **) |
| 8 | 5M2894 | WASHER-HARD (IF NEEDED **) |
| 2 | 9S8752 | NUT-FULL (IF NEEDED **) |
| 12 | 9X6458 | WASHER-HARD (IF NEEDED **) |
| 2 | 2295332 | GASKET (IF NEEDED **) |
| 1 | 2847633 | BRACKET AS. (IF NEEDED **) |
| 1 | 2847634 | BRACKET AS. (IF NEEDED **) |
| 1 | 2922971 | RISER AS. (IF NEEDED **) |
| 1 | 2922972 | RISER AS. (IF NEEDED **) |
| 1 | 2925555 | BRACKET (IF NEEDED **) |
| 1 | 2925556 | BRACKET (IF NEEDED **) |
| 4 | 2933286 | SPACER (IF NEEDED **) |
| 1 | 3065140 | TUBE AS. (IF NEEDED **) |
| In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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. **NOTE: Refer to attached Rework Procedure to determine parts ordering quantities based on Right Side or Left Side repair. | ||
| *******Group 2******* | ||
| 6 | 0L2070 | BOLT (IF NEEDED **) |
| 4 | 0S1591 | BOLT (IF NEEDED **) |
| 2 | 2Y9255 | SPACER (IF NEEDED **) |
| 12 | 9X6458 | WASHER-HARD (IF NEEDED **) |
| 2 | 2295332 | GASKET (IF NEEDED **) |
| 1 | 2847633 | BRACKET AS. (IF NEEDED **) |
| 1 | 2847634 | BRACKET AS. (IF NEEDED **) |
| 1 | 2922971 | RISER AS. (IF NEEDED **) |
| 1 | 2922972 | RISER AS. (IF NEEDED **) |
| 1 | 2925555 | BRACKET (IF NEEDED **) |
| 1 | 2925556 | BRACKET (IF NEEDED **) |
| 4 | 2933286 | SPACER (IF NEEDED **) |
| In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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. **NOTE: Refer to attached Rework Procedure to determine parts ordering quantities based on Right Side or Left Side repair. | ||
ACTION REQUIRED
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| Replace the 4P-8251 and 4P-8252 Water-cooled Exhaust Risers. Refer to the attached Rework Procedure. |
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SERVICE CLAIM ALLOWANCES
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| *******Group 1******* | ||||||
0-12 mo |
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13-24 mo |
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25-36 mo |
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| NOTE: This is a 8.0-hour job for Group 1 | ||||||
| This service letter is only to repair the riser that has failed, it does not cover replacement of the non-failed riser on the opposite side of the engine. |
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| *******Group 2******* | ||||||
0-12 mo |
||||||
13-24 mo |
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25-36 mo |
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| NOTE: This is a 8.0-hour job for Group 2 | ||||||
| This service letter is only to repair the riser that has failed, it does not cover replacement of the non-failed riser on the opposite side of the engine. |
PARTS DISPOSITION
| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
| Group Number 1 |
| Rework Procedure Group 1: Engines with #0 Flywheel Housing Notes: *See Group 1 affected units *Only failed risers should be replaced. If the riser on only one side has failed, only order the parts listed for that side in the "Parts Needed" section. *See rework procedure below for failures of the riser on the right of the engine. Please note that the rework procedure for a left side failure follows the procedure for the right side failure. Refer to appropriate Service Manual as necessary. RIGHT SIDE Parts Needed for Right Side Repair: |
|
| Image1.1.1 |
| Procedure: 1. Remove Turbocharger. Refer to Turbocharger Removal Procedure, SENR5031. 2. Drain the engine coolant. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations". 3. Remove water tube (1), existing 4P-8251 Exhaust Riser, and existing riser support bracket. Exhaust riser and support bracket are not reused. Refer to Image 1.2.1. 4. Replace the 4P-8252 Riser Assembly and support brackets with the new 292-2971 Riser Assembly (2), 292-5555 Support Bracket (3), and 284-7633 Support Bracket (4). Refer to Images 1.2.1 and 1.2.2. a) Refer to Image 1.2.2. New 0S-1591 Bolts, 9X-6458 Washers, and 293-3286 Spacers are used between riser support brackets (5). 9S-8752 Nuts are reused in this location. b) New 9X-6458 Washers are used between the support bracket and exhaust riser (6). 0S-1594 Bolts are reused in this location. c) New 0L-2070 Bolts, 2Y-9255 Spacer, and 229-5332 Gasket are used at exhaust manifold flange (7). 108-3612 Spacers should be removed and 2Y-9255 Spacer should be used on the top bolt of the 3-bolt flange. 5M-2894 Washers and 9S-8752 Nuts are reused in this location. 5. Replace the hardware used in the turbo line clamp as shown in Image 1.2.3 (15). a) Add the new 0S-1594 Bolt. b) Reuse the 9S-8752 Nut. c) Reuse the 5M-2894 Washer. |
|
| Image1.2.1 |
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| Image1.2.2 |
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| Image1.2.3 |
| LEFT SIDE Parts Needed: Refer to Image 1.3.1 Procedure: 1. Remove Turbocharger. Refer to Turbocharger Removal Procedure, SENR5031. 2. Drain the engine coolant. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations". 3. Remove water tube (1), existing 4P-8251 Exhaust Riser, and existing riser support bracket. Exhaust riser and support bracket are not reused. See Image 1.3.2. 4. Replace the 4P-8251 Riser Assembly and support brackets with the new 292-2972 Riser Assembly (9), 292-5556 Support Bracket (10), and 284-7634 (11) Support Bracket (11). Refer to Images 1.3.2 and 1.3.3. a) Refer to Image 1.3.3. New 0S-1591 Bolts, 9X-6458 Washers, and 293-3286 Spacers are used between riser support brackets (12). 9S-8752 Nuts are reused in this location. b) New 9X-6458 Washers are used between the support bracket and exhaust riser (13). 0S-1594 Bolts are reused in this location. c) New 0L-2070 Bolts, 2Y-9255 Spacer, and 229-5332 Gasket are used at exhaust manifold flange (7). 108-3612 Spacers should be removed and 2Y-9255 Spacer should be used on the top bolt of the 3-bolt flange. 5M-2894 Washers and 9S-8752 Nuts are reused in this location. 5. Replace the 119-8204 Tube Assembly with the new 306-5140 Tube Assembly (Turbo oil line) (16). See Image 1.3.4. a) 126-2702 Seal, 1A-2029 Bolts, and 5M2894 Washers are reused (17). b) 112-3540 O-ring seal is reused (18). 6. Replace the hardware used in the turbo line clamp as shown in Image 1.3.4 (19). a) Replace the 1A-2029 Bolt with the new 2A-4639 bolt. b) Replace the 7W-3447 Spacer with the new 4W-9149 spacer. c) Add the new 9S-8752 Nut. d) Reuse the 5M-2894 Washer. Parts Needed for Left Side Repair: |
|
| Image1.3.1 |
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| Image1.3.2 |
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| Image1.3.3 |
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| Image1.3.4 |
| Group Number 2 |
| Rework Procedure Group 2: Engines with #1 Flywheel Housing Notes: *See Group 2 affected units *Only failed risers should be replaced. If the riser on only one side has failed, only order the parts listed for that side in the "Parts Needed" section. *See rework procedure below for failures of the riser on the right of the engine. Please note that the rework procedure for a left side failure follows the procedure for the right side failure. Refer to the appropriate Service Manual as Necessary. RIGHT SIDE Parts Needed for Right Side Repair: |
|
| Image2.1.1 |
| Procedure: 1. Remove Turbocharger. See Turbocharger Removal Procedure, SENR5031. 2. Drain the engine coolant. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations". 3. Remove water tube (1), existing 4P-8252 Exhaust Riser, and existing riser support bracket. Exhaust riser and support bracket are not reused. See Image 2.2.1. 4. Replace the 4P-8252 Riser Assembly and support brackets with the new 292-2971 Riser Assembly (2), 292-5555 Support Bracket (3), and 284-7633 Support Bracket (4). Refer to Images 2.2.1 and 2.2.2. a) Refer to Image 2.2.2. New 0S-1591 Bolts, 9X-6458 Washers, and 293-3286 Spacers are used between riser support brackets (5). 9S-8752 Nuts are reused in this location. b) New 9X-6458 Washers are used between the support bracket and exhaust riser (6). 0S-1594 bolts are reused in this location. c) New 0L-2070 Bolts, 2Y-9255 Spacer, and 229-5332 Gasket are used at exhaust manifold flange (7). 108-3612 Spacers should be removed and 2Y-9255 Spacer should be used on the top bolt of the 3-bolt flange. 5M-2894 Washers and 9S-8752 Nuts are reused in this location. |
|
| Image2.2.1 |
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| Image2.2.2 |
| LEFT SIDE Parts Needed: See attached Image 2.3.1 Procedure: 1. Remove Turbocharger. See Turbocharger Removal Procedure, SENR5031. 2. Drain the engine coolant. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations". 3. Remove water tube (1), existing 4P-8251 Exhaust Riser, and existing riser support bracket. Exhaust riser and support bracket are not reused. See Image 2.3.2. 4. Replace the 4P-8251 Riser Assembly and support brackets with the new 292-2972 Riser Assembly (9), 292-5556 Support Bracket (10), and 284-7634 Support Bracket (11). Refer to Images 2.3.2 and 2.3.3. a) Refer to Image 2.3.3. New 0S-1591 Bolts, 9X-6458 Washers, and 293-3286 Spacers are used between riser support brackets (12). 9S-8752 Nuts are reused in this location. b) New 9X-6458 Washers are used between the support bracket and exhaust riser (13). 0S-1594 Bolts are reused in this location. c) New 0L-2070 Bolts, 2Y-9255 Spacer, and 229-5332 Gasket are used at the exhaust manifold flange (7). 108-3612 Spacers should be removed and 2Y-9255 Spacer should be used on the top bolt of the 3-bolt flange. 5M-2894 Washers and 9S-8752 Nuts are reused in this location. Parts Needed for Left Side Repair: |
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| Image2.3.1 |
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| Image2.3.2 |
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| Image2.3.3 |
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