PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBOCHARGER ON CERTAIN C6.6 ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBOCHARGER ON CERTAIN C6.6 ENGINES

Usage:

REBE3165-03

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22Jan2008

(Revised 09May2008)

U-41

A-74

D-33

O-37

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBOCHARGER ON CERTAIN C6.6 ENGINES
1052 1053		PI31436

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31436" 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 "PI31436" 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 22Jan2008 (Revised 10Mar2008) Service Letter. Changes have been made to Affected Product.

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COMPLETION DATE	TERMINATION DATE
31Jul2008	31Jan2009

PROBLEM

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The seal within the turbocharger housing can wear allowing for an oil leak to occur.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C6.6 TIER 3	66603186-03187, 4681, 4852-4853, 6241-6258, 6320, 6322-6328, 6359-6374, 6464, 6526-6528

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*****Group 2*****
C6.6 TIER 3	66602684, 3120, 5075, 5267, 5348-5349, 5365-5366, 5369-5371, 5381-5404, 5411-5416, 5486, 5504, 5506-5529, 5543-5557, 5561-5574, 5580-5582, 5606-5607, 5772, 5784-5788, 5791, 5796-5798, 5857-5859, 5865-5866, 5873, 5897, 5901-5909, 6096-6107, 6109-6127, 6158-6176, 6196-6211, 6226-6230, 6260-6269, 6315-6319, 6398-6404, 6406-6409, 6419, 6439-6449, 6485-6486, 6510-6522, 6524-6525

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*******Group 3*******

C6.6 TIER 3

66604791, 4865, 4867, 5253-5254, 5323-5334, 5338-5339, 5358-5364, 5367-5368, 5373-5380, 5405-5410, 5420-5464, 5466-5471, 5474-5485, 5487-5503, 5583-5595, 5614, 5621, 5642, 5644-5651, 5653-5657, 5659-5662, 5706, 5717, 5774-5783, 5792-5795, 5799-5801, 5806-5823, 5825-5856, 5860-5864, 5867-5872, 5874-5894, 5896, 5898-5900, 5910-5951, 5953-5996, 5998-6004, 6025-6034, 6056, 6065-6076, 6078-6093, 6108, 6128-6154, 6179-6195, 6212-6225, 6231-6239, 6270-6274, 6276, 6279-6284, 6286-6288, 6292, 6294-6299, 6301-6304, 6306-6307, 6309-6311, 6313-6314, 6332-6336, 6338, 6344-6346, 6380, 6383-6385, 6388, 6390-6396, 6465-6480, 6492, 6496-6505, 6507-6509

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*****Group 4*****
C6.6 TIER 3	66605038, 5352-5356, 5372, 5417-5419, 5558-5560, 5575-5579, 5596-5605, 5622-5641, 5669, 5675-5704, 5718-5726, 5728-5733, 5735-5771, 5790, 5802, 6005-6024, 6155-6157, 6339-6343, 6437-6438, 6491

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
5	6I0217	BOLT
4	6I0563	NUT
1	1418589	GASKET-TURBO
4	1475553	STUD
2	2779939	WASHER
1	2779940	SEAL-O-RING
1	2780016	GASKET
1	2780017	GASKET
1	2892434	CLIP
1	3160397	TURBOCHARGER
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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.
*****Group 2*****
5	6I0217	BOLT
4	6I0563	NUT
1	1418589	GASKET-TURBO
4	1475553	STUD
2	2779939	WASHER
1	2779940	SEAL-O-RING
1	2780016	GASKET
1	2780017	GASKET
1	2892434	CLIP
1	3154695	TURBOCHARGER
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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.
*****Group 3*****
5	6I0217	BOLT
4	6I0563	NUT
1	1418589	GASKET-TURBO
4	1475553	STUD
2	2779939	WASHER
1	2779940	SEAL-O-RING
1	2780016	GASKET
1	2780017	GASKET
1	2892434	CLIP
1	3159810	TURBOCHARGER
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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.
*****Group 4*****
5	6I0217	BOLT
4	6I0563	NUT
1	1418589	GASKET-TURBO
4	1475553	STUD
2	2779939	WASHER
1	2779940	SEAL-O-RING
1	2780016	GASKET
1	2780017	GASKET
1	2892434	CLIP
1	3160448	TURBOCHARGER
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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Remove the turbocharger and replace with new to overcome the possibility of an oil leak.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.5-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.5-hour job for Group 2

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.5-hour job for Group 3

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.5-hour job for Group 4

PARTS DISPOSITION

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

Return removed Turbochargers to the following Addresses:

NOTE: Ensure a copy of the PI number is attached to each turbocharger with the engine serial number from which the turbocharger was removed.

For EAME:

Caterpillar Inc.
c/o Perkins Engines Ltd,
Parts Return Centre,
Peterborough,
Cambridgeshire,
PE1 5NA,
Attn: Tony Whitfield

For NACD:

Caterpillar Claims Room
BLDG C,Dock 22,
8201 N. University,
Peoria,
IL, 61615.

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

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBOCHARGER ON CERTAIN C6.6 ENGINES

MODELS INVOLVED - C6.6 INDUSTRIAL ENGINES

Dear Caterpillar Product Owner:

The Turbocharger needs to be replaced on the products listed below. The existing Turbocharger can leak oil. You will not be charged for the service performed.

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

Please refer the dealer to their Service Letter dated 22Jan2008 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 22Jan2008 Service Letter

Rework Procedure

Refer to the appropriate Service Manual as necessary.

Before removing turbocharger first check the date code of the turbocharger, which can be found on the identification plate.

The first two digits of the code represent the day of the month. The letter indicates the month. Example H = August, I = September, J = October, and K = November.