VALVE GP-SPEED SENSING 2041457 - Caterpillar

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 "PS40326"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. 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. This Revised Service Letter replaces theOctober 8, 2000 (Revised May 2001) Service Letter. Changes have been madeto the Parts Needed, Action Required, and Service Claim Allowances.TERMINATION DATE
July 31, 2002PROBLEM
Turbochargers on certain 824G, 825G, and 826GCompactors, 980G Wheel Loaders, and listed CIPI machines have been failingdue to cyclic fatigue of the turbo compressor wheel. The high cycle rateof these machines may cause premature failure of the compressor wheel.AFFECTED PRODUCT
Model Identification Number980G 2KR1-3763
2SR1-659
9CM1-1675824G 4SN1-444825G 6RN1-375826G 7LN1-611CIPI Machines 05A11356, 11357,11478, 11479, 11705, 12508, 12509,
12511, 12512, 12655, 12659, 12660, 12661, 12662PARTS NEEDED
4 - 2N2765 BOLT
4 - 2N2766 LOCKNUT
1 - OR9899 TURBO GP
1 - 1S4295 GASKET-TURBO
1 - 1S4810 GASKET-OIL
1 - 1S6595 GASKET
1 - 1142687 SEAL-O-RING
1 ? 1210173 PLATE-INFO
1 ? 1287794 BOLT
1 ? Lockwire for re-sealing the fuel air ratiocontrol
1 ? Dealer Seals for re-sealing the fuel airratio control Additional parts are also needed toperform PI10030. Refer to Service Letter dated May 11, 2001.ACTION REQUIRED
1. Remove turbo supply and drain lines.2. Remove failed turbocharger.3. If repair is performed after a turbochargerfailure, inspect air transfer pipes between air cleaner and turbochargerfor debris. If necessary, clean aftercooler of any debris or oil contaminationand replace damaged air piping seals or bolts. Inspect and clean any debrisfrom the exhaust system and muffler.4. Install replacement turbo using new turbo/manifoldflange gasket, and new flange nuts and bolts.5. Install turbo supply line using new gasket.6. Install turbo drain line using new gasketand seal. Lubricate bore of lower tube elbowwith engine oil prior to inserting drain tube and seal in bore.7. Adjust the "FUEL AIR RATIO DYNAMIC SETTING"value per the following table. When completed, install new lockwire, newtamperproof bolt, and Dealer seals to the control
Application Fuel Air Ratio Dynamic Setting
980G and listed CIPI machines +.65mm
824G/825G/826G +.77mm
8. Use an indelible black marker to markout the former "A/F RATIO DYNAMIC SETTING" value on the 115-5852 EngineInformation Label which is located on top of the valve cover. Stamp thenew A/F RATIO DYNAMIC SETTING" value fuel setting on a new metal 121-0173Plate (replacement plate). Also stamp the new plate with the other engineinformation that has not changed. In the "MODIFICATION NO." field of thenew plate stamp the following "USE THIS A/F RATIO SETTING". Install thenew metal replacement plate as close as possible to the original engineInformation