GEAR-PLANETARY 1088769 - Caterpillar

SEBE9430 December 13, 2005
U-392
A-291
D-308
O-328
Beforeor
after failureParts stock action needed PRODUCT SUPPORT PROGRAM FOR REPLACINGTURBOCHARGERS ON CERTAIN 3500 SERIES ENGINES
1052 PS41938
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS41938"as the Part number and "7755" as the Group Number. If administered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If administered after failure, use "96" as theWarranty Claim Description Code and use "Z" as the SIMS Description Code. Although this Program is to be administeredas described above on the Affected Product, parts should be removed fromparts stock as soon as possible. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
December 13, 2007PROBLEM
The 2454339/">245-4339 turbo is failing during commissioning,at very early hour, at multiple sites. Preliminary inspection of failedturbochargers indicates the turbochargers are experiencing over speed /over temp for the compressor wheel causing the compressor wheel to becomeunbalanced, rub then fail. In addition the turbo manufacture is havingproblems with the balancing of the turbo rotating assembly. Turbo manufacturerreviewed their balancing process and noted a change that took place duringa period of operation that also coincides with the date codes on the failedturbochargers.AFFECTED PRODUCT
Model IdentificationNumber
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, 1966,1970-1973BPJ457-497FDN1475-1500, 1502-1504, 1508-1513,1515-1520, 1522-1525, 1528, 1531, 1534-1535, 1539-1541, 1543-1668, 1670-1679,1681-1684, 1699-1730, 1735-1783FDX235, 251, 253-261, 264-269, 272-280GAR111-136, 138, 140-144ZAP114
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 PPS156PARTS NEEDED
Qty
Part Number Description
* 2454339 TURBO GP-BAS* Order only the number needed afterthe inspection has been completed.ACTION REQUIRED
***** Parts Stock *****Remove all 2454339 Turbochargers from partsstock.***** 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 removethe turbocharger from the engine.
After the turbocharger is removed, replace theturbocharger 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 removethe turbocharger from the engine.
After the turbocharger is removed, replace theturbocharger using publication "Turbocharger - Install ? Center MountedTurbocharger", SENR6564.
SERVICE CLAIM ALLOWANCES
***** Parts Stock *****Submit one claim for all 2454339 Turbochargersthat are removed from parts stock.***** Affected Product *****