PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE TURBOCHARGERS ON CERTAIN 3412C GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE TURBOCHARGERS ON CERTAIN 3412C GENERATOR SETS

Usage:

TEBE1492-01

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01Aug2014

(Revised 22Sep2014)

U-456

A-332

D-403

O-385

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE TURBOCHARGERS ON CERTAIN 3412C GENERATOR SETS
1052		PI32378

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32378" 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 "PI32378" as the Part Number, "7751" as the Group Number, "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 01Aug2014 Service Letter. Changes have been made to the Affected Product.

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COMPLETION DATE	TERMINATION DATE
28Feb2015	31Aug2015

PROBLEM

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The turbochargers need to be inspected on certain 3412C Generator Sets. The existing tubochargers can prematurely fail the thrust washer.

AFFECTED PRODUCT

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Model

Identification Number

3412C

RTY03526-03536, 3539, 3541, 3543, 3545-3546, 3548, 3550, 3552, 3554, 3556-3558, 3561-3563, 3613, 3685-3690, 3776, 3778-3784, 3786-3789, 3791, 3793-3798, 3801, 3803-3805, 3807, 3810-3827, 3830-3842, 3846, 3848, 3855-3864, 3867-3870, 3872, 3874, 3876-3879, 3882, 3887, 3891, 3897-3904, 3906-3915, 3917, 3920-3927, 3929-3930, 3933-3934, 3944-3945, 3947-3949, 3951-3952, 3960, 3968-3975, 3978-3981, 3983, 3985, 3988, 3990-3994, 3996-3999, 4002-4006, 4008, 4010, 4013-4022, 4024-4025, 4124, 4127, 4131, 4135, 4140, 4142-4143, 4145-4148, 4161, 4163-4166, 4168-4170, 4172, 4174

TGC01062, 1064-1080, 1082-1101, 1103-1105, 1107, 1109-1110

PARTS NEEDED

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Qty	Part Number	Description
2	1S4295	GASKET-TURBO (AS NEEDED)
8	2N2765	BOLT-HEX FLG HD (AS NEEDED)
8	2N2766	LOCKNUT (AS NEEDED)
2	4P2783	TURBO GP-BASIC (AS NEEDED)
2	5P7530	SEAL-O-RING
8	6V3917	SEAL-O-RING
4	6V5103	SEAL-O-RING
6	7E4369	SEAL AS-EXHAUST
2	1986068	SEAL-INTEGRAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% 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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Inspect the turbochargers for thrust bearing wear.

Note: Only replace turbochargers that do not meet the endplay measurements set forth in this program.

Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.5-hour job
An additional 1 hour is allowed for each turbo if replacement is necessary.

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PARTS DISPOSITION

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

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

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE TURBOCHARGERS ON CERTAIN 3412C GENERATOR SETS

MODELS INVOLVED - 3412C

Dear Cat Product Owner:

The turbochargers need to be inspected on the products listed below. The existing turbochargers can fail the thrust bearing at less than 100 hours. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 01Aug2014 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 01Aug2014 Service Letter

Rework Procedure

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RIGHT SIDE:

1. Loosen nut on 5L9316 Clamp to allow removal of 9Y7552 Tube Assembly.

Image1.1.1

2. Loosen two 0S0509 Bolts securing 9Y6661 Clamp to 9Y7552 Tube Assembly.

Image1.2.1

3. Slide 9Y7552 Tube Assembly rearward to allow access to turbine wheel of turbo.

4. Loosen two 0S1594 Bolts securing 9Y6116 Bracket to 9Y7045 Tube Assembly (Elbow).

Image1.4.1

5. Loosen nut on 5L9316 Clamp to allow separation of 9Y7551 Tube Assembly from 9Y7045 Tube Assembly (Elbow).

Image1.5.1

6. Remove four 0S1594 Bolts and 5M2894 Washers securing 9Y6116 Bracket to 9Y6114 Bracket Assembly.

Image1.6.1

7. Remove 0S1594 Bolt, 9S8752 Nut and 2- 5M2894 Washer securing 110-5978 Tube Assembly (oil fill) to 110-6157 Clip on 9Y7551 Tube Assembly.

Image1.7.1

8. Raise 9Y7551 Tube Assembly slightly and remove 9Y7045 Tube Assembly (Elbow), 9Y6116 Bracket and 9Y7080 Pipe (adapter) from compressor inlet of turbo.

Image1.8.1

9. Move turbo shaft fully toward turbine side of turbo by pushing on the end of the shaft inside the compressor housing.

10. Position tip of dial indicator against end of shaft (also acceptable to place on machined surface of compressor wheel next to nut) and zero the dial indicator.

Image1.9.1

11. Move turbo shaft fully toward the compressor side of the turbo by pushing on the end of the shaft inside the turbine housing and note indicator movement. Maximum movement allowed is .11 millimeters.

12. If measurement exceeds .11 mm the turbo will need to be replaced according to instructions in RENR1389.

13. If measurement is .11 mm or less, reassemble air system and touch up paint as needed.

Image1.10.1

LEFT SIDE:

1. Loosen nut on 5L9316 Clamp to allow removal of 9Y7553 Tube Assembly.

Image1.11.1

2. Loosen two 0S0509 Bolts securing 9Y6661 Clamp to left side exhaust pipe.

Image1.12.1

3. Slide 9Y7553 Tube Assembly rearward to allow access to turbine wheel of turbo

Image1.13.1

4. Loosen nut on 5L9316 Clamp to allow separation of 9Y7555 Tube Assembly from 9Y7554 Tube Assembly (Elbow).

5. Loosen two 0S1594 Bolts securing 9Y6115 Bracket to 9Y7554 Tube Assembly (Elbow).

Image1.15.1

6. Remove four 0S1594 Bolts and 5M2894 Washers securing 9Y6115 Bracket to 9Y6114 Bracket Assembly.

Image1.16.1

7. Raise 9Y7555 Tube Assembly slightly and remove 9Y7554 Tube Assembly (Elbow), 9Y6115 Bracket and 9Y7080 Pipe (adapter) from compressor inlet of turbo.

Image1.17.1

8. Move turbo shaft fully toward turbine side of turbo by pushing on the end of the shaft inside the compressor housing.

9. Position tip of dial indicator against end of shaft (also acceptable to place on machined surface of compressor wheel next to nut) and zero the dial indicator.

Image1.18.1

10. Move turbo shaft fully toward the compressor side of the turbo by pushing on the end of the shaft inside the turbine housing and note indicator movement. Maximum movement allowed is .11 millimeters.

11. If measurement exceeds .11 mm the turbo will need to be replaced according to instructions in RENR1389.

12. If measurement is .11 mm or less, reassemble air system and touch up paint as needed.

Image1.19.1

Note: It may be necessary to loosen the two 0S1587 Bolts securing the 9Y6665 Rear Bracket Assembly to the cylinder head to achieve proper alignment of the 9Y7553 Tube Assembly during reassembly. Retighten bolts after 5L9316 Clamp is secured.