PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGERS, LINES GROUP, AND SOFTWARE ON CERTAIN 241-0021, 308-0037, AND 316-0039 ENGINE ARRANGEMENTS INSTALLED IN TEREX O&K SHOVELS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGERS, LINES GROUP, AND SOFTWARE ON CERTAIN 241-0021, 308-0037, AND 316-0039 ENGINE ARRANGEMENTS INSTALLED IN TEREX O&K SHOVELS

Usage:

REBE5290-01

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03Sep2009

(Revised 18Nov2009)

U-313

A-263

D-279

O-287

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGERS, LINES GROUP, AND SOFTWARE ON CERTAIN 241-0021, 308-0037, AND 316-0039 ENGINE ARRANGEMENTS INSTALLED IN TEREX O&K SHOVELS
1053 1052 1920 1901 1380		PS42964

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42964" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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 03Sep2009 Service Letter. Changes have been made to Affected Product.

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TERMINATION DATE

30Sep2010

PROBLEM

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The existing turbochargers may fail on certain 241-0021, 308-0037, and 316-0039 engine arrangements installed in certain Terex O&K Shovels. The current turbocharger may surge due to rapid engine deceleration. The surge may cause the turbocharger to fail.

AFFECTED PRODUCT

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Model

Identification Number

C18

WJH00222, 224, 226, 297, 358, 369, 551, 564, 573, 691, 713, 869, 872, 875, 878, 899, 901, 905, 908, 910, 912, 1095, 1104, 1111, 1118, 1220, 1225, 1229, 1232, 1234, 1240-1241, 1305, 1345, 1356, 1392, 1397, 1484-1485, 1490, 1494, 1532, 1534, 1570, 1576, 1584, 1591, 1666, 1672, 1751, 1755, 1773, 1777, 1781, 1784, 1844, 1849, 1852, 1858, 2030, 2051, 2056, 2095, 2098-2099, 2109, 2699, 2715, 2722, 2727, 2828, 2852, 2854, 2887, 2926, 2946, 2959, 2967, 2970, 2974, 3115-3117, 3119, 3145-3147, 3153, 3159, 3551, 3608, 3611, 3625-3626, 3632, 3634, 3638, 3643, 3648-3649, 3653, 3661, 3722, 3724, 3728, 3742, 3744, 3749, 3755, 3832, 3844, 3854, 3860, 3863, 3865, 3870, 3872-3873, 3875-3876, 3898, 3902, 3904-3905, 4080-4081, 4085, 4218-4219, 4222, 4229, 4231, 4350, 4352, 4366, 4369, 4371-4372, 4623-4624, 4638-4639, 4642, 4647, 4782, 4784, 4811, 4813, 4818-4819, 4933, 4935-4938, 4949-4950, 4954, 4958, 5117-5118, 5122, 5124, 5130-5132, 5252, 5258, 5265, 5319, 5325, 5335, 5338-5339, 5344, 5347, 5396, 5444, 5446, 5453, 5531-5536, 5711, 5715, 5717, 5722, 5752, 5758, 5760-5761, 5765, 6036, 6047, 6116, 6138, 6140, 6189, 6200-6201, 6203, 6205-6208, 6260, 6267, 6311-6312, 6357, 6360, 6362-6363, 6398, 6444, 6449, 6493, 6565-6568, 6634-6636, 6737, 6774, 6776-6777, 6779-6780, 6801, 6803, 6806, 6808-6809, 6821, 6828-6829

PARTS NEEDED

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Qty	Part Number	Description
1	0L1351	BOLT
5	0S0509	BOLT
8	2N2765	BOLT-FLANGE HEAD
8	2N2766	LOCKNUT
2	3P2001	ELBOW
1	4D9517	CLIP
7	5M2894	WASHER-HARD
1	5P3166	TEE-SWIVEL
1	6V5063	SEAL-O-RING
5	6V6609	SEAL-O-RING
1	7F2050	LOCKNUT
1	7M7273	GASKET-TURBO
2	8M0505	CONNECTOR-FLARED
1	8M0547	ELBOW
1	8T4994	WASHER-HARD
1	9L1566	SUPPORT-TUBE
1	9S8752	NUT-FULL
1	0308110	CONNECTOR-O-RING
1	0308189	CONNECTOR-FLARED
1	0618408	TEE-FLARED
1	2705094	HOSE AS.
2	3222477	TUBE AS-TURBO W
1	3222478	TUBE AS-TURBO W
1	3222479	TUBE AS-TURBO W
1	3222480	BRACKET AS
1	3442670	SOFTWARE GP-ELEK
2	3456947	TURBO GP-BASIC
1	3517365	SOFTWARE GP-ELEK
1	LABEL	EMISSIONS CERTIFICATION LABEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% 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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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-12000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 7.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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Engine Emissions Label

1. Begin at the SISWeb homepage. The address is https://sis.cat.com

2. From the SISWeb homepage, select the Engine Technical Marketing Information ? TMI link.

3. Once in TMI, input the serial number of the engine into the reference number box and select "serial number" in the drop down menu.

4. Press the "Retrieve Data" button.

5. Select the "Emissions Data" link.

6. Scroll to the bottom and click the link titled, "Need emissions replacement label ? Click Here!." This will direct the user to the Large Power Systems Division Homepage.

7. Click on the emissions/certification replacement link.

8. Complete the dealer name and information. Reference Image1.2.1

Image1.2.1

9. Complete the remaining fields highlighted with a red asterisk.

10. Select "Engine Iformation Label" as the label type. Enter the number of this Priority Program in the field titled "Reason for replacement label request." It is important to have the engine serial number field completed with the correct information. Reference Image 1.3.1

NOTE: Be sure that the correct shipping information is provided. International requests must have a valid UPS or DHL account number.

11. After receiving the new emissions label, remove the old label and install the new label. Location of the new label should be on the top of the front valve cover or on the engine oil cooler.

Turbocharger Removal

1. Remove the turbochargers. Refer to Disassembly and Assembly ? RENR8630 ? "Turbocharger ? Remove ? Dual Turbocharger."

Turbocharger Installation

1. Install the turbochargers using new 1S-4295 gaskets, 2N-2765 bolts, and 2N-2766 nuts.

2. Refer to Disassembly and Assembly ? RENR8630 ? "Turbocharger ? Install ? Dual Turbocharger." Reference Image 1.7.1

Image1.7.1

Water Line Installation
1. Install 322-2480 bracket (1) to the exhaust elbow using four 5M-2894 Washers (2) and four 0S-0509 Bolts (3). Reference Image 1.8.1

2. Install 6V-5063 O-Ring (4), 030-8189 Connector (5), and 8M-0547 Elbow (6) to the water bonnet. Reference Image 1.9.1

Image1.9.1

3. Attach 270-5094 Hose Assembly (7) to the 8M-0547 Elbow (6).

Image1.10.1

4. Insert 061-8408 Tee (8) into the 322-2480 Bracket (1) using 8T-4994 Washer (9) and 7F-2050 Locknut (10). Reference Image 1.10.1

Image1.11.1

5. Attach 270-5094 Hose Assembly (7) to the 061-8408 Tee (8). Reference Image 1.12.1

Image1.12.1

6. Attach 322-2477 Tube Assembly (11) to the 061-8408 Tee (8). Reference Image 1.13.1

Image1.13.1

7. Attach the 3P-2001 Elbow (13) and the 6V-6609 O-Ring (12) to the turbocharger. Attach 3P-2001 Elbow (13) to the 322-2477 Tube Assembly (11). Reference Image 1.14.1

Image1.14.1

8. Attach 322-2477 Tube Assembly (14) to the 061-8408 Tee (8). Reference Image 1.15.1

Image1.15.1

9. Attach 3P-2001 Elbow (15) and 6V-6609 O-Ring (16) to the turbocharger. Attach the 3P-2001 Elbow (15) to the 322-2477 Tube Assembly (14). Reference Image 1.16.1

Image1.16.1

10. Insert 6V-6609 O-Ring (17) and 8M-0505 Connector (18) into the turbocharger. Reference Image 1.17.1

Image1.17.1

11. Attach 322-2478 Tube Assembly (19) to the 8M-0505 Connector (18). Reference Image 1.18.1

Image1.18.1

12. Attach 6V-6609 O-Ring (21) and 030-8110 Connector (22) to the turbocharger. Also connect the 030-8110 Connector to the 5P-3166 Tee (20). Reference Image 1.19.1

Image1.19.1

13. Attach 322-2478 Tube Assembly (19) to 5P-3166 Tee (20). Reference Image 1.20.1

Image1.20.1

14. Install 322-2479 Tube Assembly (23) to the 5P-3166 Tee (20). Reference Image 1.21.1

Image1.21.1

Image1.21.2

15. Install the OEM Coolant Return Line to the reflie valve (24). Install 6V-6609 O-Ring (25) and 8M-0505 Connector (26) to the water pump. Attach the 8M-0505 to the 322-2479 Tube Assembly (23). Reference Image 1.21.2

16. Attach 4D-9517 Clip (27) onto 322-2478 Tube Assembly (19). Reference Image 1.23.1

Image1.23.1

17. Attach 9L-1566 Support (28) to the 4D-9517 Clip (27) using 5M-2894 Washer (29), 0L-1351 Bolt (30), 5M-2894 Washer (31), and 9S-8752 Nut (32). Reference Image 1.24.1

Image1.24.1

18. Attach the 9L-1566 Tube Support (28) to the cylinder head using 0S-0509 Bolt (33) and 5M-2894 Washer (34).

Image1.25.1

ECM Reflash

NOTE: There are two flashfiles that can be used. Flashing the ECM with the incorrect software and hardware combination can lead to unacceptable engine performance. Please check the table for which software is applicable to your setup. Reference Image 1.26.1

NOTE: Factory passwords may be required.