Inspecting and Repairing the Air Inlet and Exhaust System After Improper Fueling{1000, 1052, 1053, 1061, 1087} Caterpillar

Engine:

C13 (S/N: S3C1-UP; LEE1-UP)

C15 (S/N: SDP1-UP; B5R1-UP)

C7 (S/N: C7S1-UP)

C9 (S/N: C9S1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read this information and you understand this information.

This Special Instruction provides guidelines for the identification of improper fueling, determining the severity of the condition and the appropriate repair procedure to correct this problem.

Model Year 2007 Caterpillar On-highway Diesel Engines require the use of Ultralow Sulfur Diesel fuel (ULSD) in order to meet the United States Environmental Protection Agency 2007 emissions regulations for on-highway diesel engines. Using other diesel fuel is called improper fueling.

Improper fueling can increase the amount of sulfuric acid in the air system. The increased amount of sulfuric acid can damage the following air system components:

• CGI Mixing Valve

• Both Turbochargers

• Air Ducting

• CGI Cooler

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Sulfuric Acid Burn Hazard, may cause serious personal injury. The clean gas induction cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the CGI cooler during service of the engine and may travel to other downstream components. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.

This Special Instruction has three sections:

Inspecting the Components - Air system components are inspected in a logical sequence. The inspection determines the level of damage to the air system components.

Cleaning Procedure - A cleaning procedure is described.

Disposition of the CGI Cooler - This procedure describes the correct way to dispose of the CGI cooler.

Note: For the correct maintenance procedures, refer to the engine's Disassembly and Assembly manual.

Inspecting the Components

Note: A deteriorated turbocharger wastegate line may be a indication of improper fueling.

Begin inspecting the components with the CGI mixing valve.

CGI Mixing Valve

1. Remove the air inlet duct between the air cleaner and the CGI mixing valve.

2. Look into the inlet of the CGI mixing valve. Compare the inlet to Illustration 1 and Illustration 2.

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Illustration 1	g01386785
Clean CGI mixing valve

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Illustration 2	g01386358
Corroded CGI mixing valve Additional inspections are required.

3. If the CGI mixing valve appears clean, no additional maintenance is required. Install the air inlet duct and return the vehicle to service.

4. If the CGI mixing valve has corrosion, additional inspections are required. Continue to the compressor housing for the low pressure turbocharger.

Compressor Housing for the Low Pressure Turbocharger

1. Remove the duct from the compressor housing for the low pressure turbocharger.

2. Compare the compressor housing with Illustration 3. If the housing appears clean, no additional maintenance is required. Install the air inlet duct and return the vehicle to service.

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Illustration 3	g01387849
Corroded compressor housing

3. If the housing looks like Illustration 3, additional inspections are required. Continue to the low pressure turbocharger compressor wheel.

Low Pressure Turbocharger Compressor Wheel

1. Remove the compressor housing from the low pressure turbocharger.

2. The inspection points are indicated in Illustration 4. Compare the compressor wheel with Illustrations 4, 5, and 6.

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Illustration 4	g01387719
Clean compressor wheel The inspection points are shown. (1) Look for physical damage. (2) Look for physical damage and indications of contact with the compressor housing

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Illustration 5	g01387725
Compressor wheel with minor damage This level of damage is acceptable.

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Illustration 6	g01387727
Compressor wheel with severe damage This level of damage is unacceptable.

3. Refer to the following information in order to determine the additional maintenance that must be performed.

   The Compressor Wheel is Clean - Components of the air system must be cleaned. Refer to ""Cleaning Procedure" ".

   The Compressor Wheel Has Minor Damage - The turbocharger is OK. Components of the air system must be cleaned. Refer to ""Cleaning Procedure" ".

   The Compressor Wheel Has Severe Damage - Perform the following maintenance:

   • Clean the components of the air system. Refer to ""Cleaning Procedure" ".

   • Replace the cartridge for the low pressure turbocharger.

   • Replace the CGI cooler. Refer to ""Disposition of the CGI Cooler" ".

Cleaning Procedure

1. Remove all connections and tubes between the CGI cooler and the precooler (if equipped). Also, remove the compressor housing.

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Illustration 7	g01387868
Compressor housing before the compressor housing is cleaned

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Illustration 8	g01387853
Compressor housing after the compressor housing is cleaned

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Illustration 9	g01389727
Bellows assembly before the bellows assembly is cleaned

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Illustration 10	g01391763
Bellows assembly after the bellows assembly is cleaned

2. Clean the components in a washer. Refer to Guideline for Reusable Parts and Salvage Guidelines, SEBF8363. Refer to Illustrations 8, 7, 9, and 10.

Disposition of the CGI Cooler

Do not replace the CGI cooler unless the compressor wheel has severe damage.

1. Remove the CGI cooler from the engine. Be sure to follow the procedure in the engine's Disassembly and Assembly manual.

2. Immediately submerge the CGI cooler in water.

3. Remove the caps from the ends of the CGI cooler.

4. Allow the water to circulate through the CGI cooler in order to dilute any sulfuric acid that may be present.

5. Dispose of the CGI cooler according to local regulations.

6. Dispose of the water.

7. Install a new CGI cooler.

8. Apply 295-8454 Film .

9. Install the remaining components for the air system.

10. Perform a stationary regeneration. The stationary regeneration cleans the catalyst in the diesel particulate filter (DPF).