0392114 JOHNSON HOUSING & COVER ASSY.

Introduction
Table 1
Revision History
Revision Summary of Changes
01 Removed C7.1 from the title and Table 2. Added C7 and C9 to the title and Table 2.
02 Changed Effectivity
03 Changed Effectivity Turbochargers are being replaced in the field and returned to Caterpillar for inspection. Results of the inspection are finding a large portion of the returns to be no fault found with the turbocharger or the turbocharger not being the root cause of failure.Very often turbochargers are damaged or appear to be damaged as a downstream effect of a different part causing failure. In these cases, the warranty claim must be written under the actual part causing failure; a claim written under a turbocharger, even if it is damaged, will be debited if the turbocharger is found to not be the initial cause of failure. Likewise, turbocharger failure claims whose cause is the result of improper maintenance or abuse will also be debited. Turbochargers returned without their original nameplates too will result in debits. All remains of the turbocharger causing failure must be returned.In any case that a turbocharger is being replaced, this turbocharger Troubleshooting return form needs to be completed and included with failed part returns documenting what was found that led to turbocharger replacement. As the form directs, attach photos of the turbocharger and mount area along with a Product Status Report to the SIMS claim.Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.Note: This special instruction does NOT apply to C7.1 engines.References Section
Table 2
Engine Publication Type Media Number
C7 Troubleshooting KENR5407
Testing and Adjusting SENR9939
Disassembly and Assembly RENR9218
C9 Troubleshooting RENR2418
Testing and Adjusting RENR7597
Disassembly and Assembly RENR7460
C9.3 Troubleshooting UENR0978
Testing and Adjusting UENR3402
Disassembly and Assembly UENR0130
C13 Troubleshooting UENR0955
Testing and Adjusting UENR4302
Disassembly and Assembly UENR0131
C15/C18 Troubleshooting UENR0955
Testing and Adjusting UENR3351
Disassembly and Assembly UENR0132 Procedure
What code/symptom are you Troubleshooting? __________
Follow the correct Troubleshooting procedure. Reference Table 2 for correct media number to use.
Use the Troubleshooting guide to complete the requested information in tables 3 through 8.Quality Check List
Table 3
Turbine Side Oil Seal Leak
Potential Engine Symptoms: Low Power, Smoke, High Oil Consumption, Oil Leak from Exhaust System Joints
Step Potential Cause Additional Data Needed Completed Result
1 Extended idle/low load factor. ECM Download (Product Status Report with Histogram). Is the load factor <25%?
2 Turbo oil return line restriction due to line damage or sharp bends. Photos of turbo oil return line.
3 Turbo oil return line restriction due to overfilled crankcase. Oil level below max gauge line? (Yes / No)
4 Exhaust leak upstream of turbine inlet. Photos of pre-turbine soot leaks.
5 Engine oil ingestion at turbine inlet. Photos of turbine inlet and exhaust manifold joints.
6 Excessively high crankcase pressure. ECM Download (Product Status Report with Histogram). Are there any codes present?
Is the OCV filter pasted the maintenance interval?
Is the blowby volume greater than two times rated horsepower?
7 Excessively low turbine outlet pressure. Exhaust ventilation system in application? (Yes / No)
Table 4
Compressor Side Oil Seal Leaking
Potential Engine Symptoms: Low Power, Smoke, High Oil Consumption, Oil Leak from Air System Joint, Engine Runaway
Step Potential Cause Additional Data Needed Completed Result
1 Extended idle/low load factor. ECM Download (Product Status Report with Histogram). Is the load factor <25%?
2 Excessively low compressor inlet pressure due to inlet hose collapsing. Photos of compressor inlet hose.
Is compressor inlet hose damaged? (Yes / No)
Does the compressor inlet hose collapse on engine acceleration? (Yes / No)
Is the filter minder tripped? (Yes / No)
Provide air system repair history.