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 [REBE3197]

AIR INLET AND EXHAUST SYSTEM

TURBOCHARGER GP

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

REBE3197-02

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22Jan2008

(Revised 09May2008)

U-40

A-36

D-32

O-36

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBOCHARGER ON CERTAIN C6.6 ENGINES
1052 1053		PI31435

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31435" 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 "PI31435" 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 AVSpare product analyst.

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NOTE:	This Revised Service Letter replaces the 22Jan2008 (Revised 12Mar2008) 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*****
D6K LGP	DHA00514, 532-537, 539-555, 557-598, 602, 605
D6K XL	FBH00698, 702-705, 710-719, 721-722, 724-728, 730-741, 743-767, 769-770
D6N LGP	DJY00703, 765-766, 771-775, 777-787, 789-795, 798, 800, 802-806, 810-811, 813-822, 824-825, 827-839, 841-842, 844-893, 896, 898, 901-902
D6N XL	DJA00566, 584, 588-589, 593, 596, 598, 600-602, 604-610, 612-614, 616-620, 622-649, 651-658, 660-661

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*****Group 2*****
120M	B9C00132, 145, 147-148
12M	B9F00015-00017, 20-27, 29-32, 34-36, 38-39, 41, 44-48, 50-53, 56, 60, 63-79, 81, 83, 85-86, 88, 91, 93-94, 96, 98-99, 102, 105-107, 113-115, 117-118, 120, 125, 128-129, 131, 135, 141, 151, 155, 161, 174-179, 184-185, 188, 199, 201
953D	LBP00404, 406-434, 436-439, 441-454, 460
PL61	WGS00100

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*****Group 3*****
924H	JTM00214, 216-218, 220, 222-226, 228-229, 231-232, 234-235, 237, 239-254, 256-264
924H Z	PED00243, 246-252, 255-260, 262-266, 268, 271, 273-275, 277, 279-281, 284
928H	BYD00177, 182, 184-192, 194-198, 200, 205-241
930H	FTD00193-00200, 203-228
M316D	W6A00626-00627, 629-646, 648-650, 657, 660, 668
M318D	W8P00606, 608, 610-613, 615-623, 625, 627-629, 631, 636, 638-641, 645, 666 W8R00211-00213, 215-216, 218, 223
M322D	W2S00274, 277

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*****Group 4*****
D6K XL	NCF00012-00013, 15-27, 30-39

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*****Group 5*****
963D	LCS00273, 285-286, 288, 292-293, 295-297, 299-474, 700-710, 712-715

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	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 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	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 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	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	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 5*****
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	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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Inspect the turbo charger date code. Remove the turbocharger and replace with new to overcome the possibility of an oil leak.

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OWNER NOTIFIAVSION

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

SERVICE CLAIM ALLOWANCES

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AVSpare		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 4.0-hour job for Group 1

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AVSpare		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 6.0-hour job for Group 2

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AVSpare		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 4.0-hour job for Group 3

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AVSpare		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 4.0-hour job for Group 4

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AVSpare		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 4.0-hour job for Group 5

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 and serial number of the engine from which the turbocharger was removed.

For EAME:

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

For NACD:

AVSpare Inc.
Engineering Parts Return Area
Building DD, Dock 8
Route 29 & Old Gelena Road
Mossville, Illinois 61552

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

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COPY OF OWNER NOTIFIAVSION 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 - 924H, 924H Z, 928H, 930H, 953D, D6K LGP, D6K XL, D6N LGP, D6N XL, PL61, M316D, M318D

Dear AVSpare 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 AVSpare 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.

AVSpare Inc.

Identification #(s)

Attached to 22Jan2008 Service Letter

Rework Procedure

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. For example H = August, I = September, J = October and K = November. Refer to Image 1.1.1.