PRODUCT SUPPORT PROGRAM FOR UPDATING THE SOFTWARE AND POSSIBLY CLEANING THE TURBOCHARGER COMPRESSOR HOUSING ON CERTAIN C7 AND C9 ON-HIGHWAY ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE SOFTWARE AND POSSIBLY CLEANING THE TURBOCHARGER COMPRESSOR HOUSING ON CERTAIN C7 AND C9 ON-HIGHWAY ENGINES

Usage:

REBE8297-03

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25Jul2012

(Revised 13May2013)

U-390

A-311

D-340

O-359

TT-3

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE SOFTWARE AND POSSIBLY CLEANING THE TURBOCHARGER COMPRESSOR HOUSING ON CERTAIN C7 AND C9 ON-HIGHWAY ENGINES
1901 1920 1052		PS43659

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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 "PS43659" 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 25Jul2012 (Revised 14Sep2012) Service Letter. A change has been made to Action Required.

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TERMINATION DATE

31Jul2013

PROBLEM

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The existing software can allow a pressure imbalance in the turbocharger under certain operating conditions on certain C7 and C9 On-Highway Engines. If the existing turbocharger experiences a pressure imbalance, oil may leak past the seals. Also some engines may perform a system regeneration more frequently than desired, less than 5 hours between regens.

AFFECTED PRODUCT

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Model	Identification Number
C7	C7S00500, 514-515, 520-527, 531, 534, 536-537, 543, 548, 553, 557-1375, 1377-1379, 1382-1383, 1385, 1387-1396, 1398-1407, 1409-1459, 1461-1467, 1469-1474, 1479, 1481-1483, 1485, 1487-1494, 1496-1497, 1500-1508, 1511-1566, 1568-1592, 1594-1610, 1612-1615, 1617-1944, 1946-2223, 2228, 2239, 2243, 2252, 2261-2262, 2264-2266, 2274, 2276, 2279, 2283, 2285-2286, 2289-2290, 2293, 2296, 2301-2792, 2794-2796, 2799-2800, 2802, 2804-2806, 2808-2811, 2814-2816, 2819-2820, 2822, 2825, 2827-2828, 2830-2836, 2839-2841, 2843-2846, 2848, 2850-2851, 2853, 2856-2858, 2863, 2868, 2874-2939, 2941-2953, 2955-3755, 3760, 3767-3768, 3778, 3785, 3787, 3790, 3799-3800, 3805-3807, 3809, 3813, 3816, 3820, 3823, 3828-3829, 3836, 3841, 3848, 3856, 3864-3865, 3868-3894, 3896-3902, 3904-3912, 3917, 3922, 3925, 3927, 3929-3930, 3932-3933, 3935-3936, 3938, 3940-3941, 3943-3946, 3949, 3952-3955, 3958-3959, 3964-3969, 3971, 3973-3977, 3979, 3981-3982, 3985, 3988-3992, 4433-4995, 4999, 5001-5002, 5004-5005, 5007-5033, 5038, 5047, 5049-6167, 6169-6181, 6183-6184, 6186-6199, 6201-6204, 6206-6208, 6210-6212, 6215-6216, 6218-6226, 6228-6230, 6232-6250, 6252-6253, 6255-6263, 6265, 6268-6331, 6333-6335, 6337-6338, 6340-6343, 6345-6356, 6358-6381, 6386-6388, 6390-7450, 7480-8985, 8988-9098, 9100-9549, 9551-9552, 9554-9999
C9	C9S00152-00177, 179, 181-187, 192-193, 197-207, 209, 215, 217, 222, 500-507, 522-523, 527, 531, 534-661, 664, 666, 668, 673-738, 740-741, 746-754, 756-762, 771, 782-841, 849-850, 852, 854-896, 898-902, 907-1006, 1009, 1015, 1017-1021, 1028-1032, 1034-1205, 1209-1319, 1324, 1328-1377, 1380-1381, 1394-1507, 1509, 1511, 1515-1532, 1534-1664, 1666-1667, 1670, 1674-1744 MFF00306-00316, 329-478

PARTS NEEDED

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Qty	Part Number	Description
4	3E8017	LOCKNUT - AS NEEDED
15	3S2093	STRAP-CABLE - AS NEEDED
1	1092332	SEAL-O-RING - AS NEEDED
1	1978419	GASKET - AS NEEDED
1	2628387	GASKET - AS NEEDED
1	2692904	GASKET-EXHAUST - AS NEEDED
2	2812592	TAPERLOCK - AS NEEDED
1	2840734	CLAMP-V-BAND - AS NEEDED
1	3841595	SOFTWARE GP-ELEK - AS NEEDED
1	3841596	SOFTWARE GP-ELEK - AS NEEDED
1	3841597	SOFTWARE GP-ELEK - AS NEEDED
1	3841598	SOFTWARE GP-ELEK - AS NEEDED
1	3841599	SOFTWARE GP-ELEK - AS NEEDED
1	3841600	SOFTWARE GP-ELEK - AS NEEDED
1	3841601	SOFTWARE GP-ELEK - AS NEEDED
1	3841602	SOFTWARE GP-ELEK - AS NEEDED
1	3841603	SOFTWARE GP-ELEK - AS NEEDED
1	3841604	SOFTWARE GP-ELEK - AS NEEDED
1	3841605	SOFTWARE GP-ELEK - AS NEEDED
1	3841606	SOFTWARE GP-ELEK - AS NEEDED
1	3841607	SOFTWARE GP-ELEK - AS NEEDED
1	3841608	SOFTWARE GP-ELEK - AS NEEDED
1	3841609	SOFTWARE GP-ELEK - AS NEEDED
1	3841610	SOFTWARE GP-ELEK - AS NEEDED
1	3841611	SOFTWARE GP-ELEK - AS NEEDED
1	3841612	SOFTWARE GP-ELEK - AS NEEDED
1	3926503	SOFTWARE GP-ELEK - AS NEEDED
1	3926504	SOFTWARE GP-ELEK - AS NEEDED
1	3926505	SOFTWARE GP-ELEK - AS NEEDED
1	3926506	SOFTWARE GP-ELEK - AS NEEDED
1	3926507	SOFTWARE GP-ELEK - AS NEEDED
1	3926508	SOFTWARE GP-ELEK - AS NEEDED
1	3926509	SOFTWARE GP-ELEK - AS NEEDED
1	3926510	SOFTWARE GP-ELEK - AS NEEDED
1	3926511	SOFTWARE GP-ELEK - AS NEEDED
1	3926512	SOFTWARE GP-ELEK - AS NEEDED
1	3926513	SOFTWARE GP-ELEK - AS NEEDED
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% 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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C7S Engines Only

Updating the software will reduce the pressure imbalance in the turbocharger which may allow oil to leak past the seals. Cleaning the turbocharger compressor housing may be needed as determined by the instructions that follow. Turbocharger failure modes other than those described below are not covered by this Service Letter.

1. Upload an ECM download into SIMS.

2. Update the engine software using Cat ET.

3. Is fault code 102-18 Engine Intake Manifold #1 Pressure : Low - Moderate Severity (2) logged-
A) No. Return the truck to service.
B) Yes. Go to Step 4.

4. Run the Air System Verification Test (ASVT).
Did engine fail the ASVT test-
A) No. Troubleshoot the 102-18 fault code. Troubleshooting is not covered by this letter as it is not related to the tubo failure being addressed via this service letter. The software update is complete.
B) Yes. Go to Step 5.

5. Upload the Air Systems Verification Test into SIMS.

6. Remove the turbocharger.

7. Remove the compressor housing from the turbocharger.

8. Clean the housing using a cleaning solution. (Stanisol and Brake Cleaner work well) (a power washer on "Low" can be used).

9. Assemble the turbocharger.

10. Run an Air Systems Verification Test.
A) Test successful and no 102-18 logged.

11. Upload the ECM download and Air Systems Verification Test into SIMS.

12. Return the truck to service.

C9S and MFF Engines

1. Upload an ECM download into SIMS.

2. Update the engine software using Cat ET.

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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%
0-150000 miles, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 5.5-hour job
For Software only update, claim 1 hour labor. Additional 0.2 labor allowed for R&I of turbo in RE chassis. Additional 0.8 labor allowed for R&I of turbo in SC chassis.

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