2004/06/01 Caterpillar

Engine:

3412E (S/N: 4CR1-UP; BDT1-UP)

3412 (S/N: 60M1-UP; 38S1-UP; 81Z1-UP)

Realignment is recommended on air system components due to cracking in the aftercooler housing. The 7N-9668 Cover has been cracking at the right side flange for the air tube from the turbocharger. The air system components need to be realigned. Use the following steps to fix the problem:

Note: The following steps are performed on the right side of the engine.

1. Install the 6N-7152 Elbow Support. Torque the bolts.

2. Install the 122-8433 Exhaust Elbow. Install the elbow with loose bolts.

3. Install the 3N-3368 Exhaust Pipe. Torque the bolts.

4. Use the 3N-3368 Exhaust Pipe as a point of prying. Push the 122-8433 Exhaust Elbow outward from the centerline of the engine. Apply pressure to the exhaust pipe. Tighten the long 3/8 bolt that is horizontal. While you are still applying pressure to the exhaust pipe, tighten the 3/8 bolt that is vertical. Tighten the clamp.

5. Install the 1W-7515 Coupling inside of the 3N-3368 Exhaust Pipe .

6. Install the turbocharger housing. Leave the nuts and the bolts loose.

7. Install the turbocharger cartridge. Leave the clamp loose. Align the tube for the oil pressure and the oil return tube. The bolts need to be loose and the gaskets need to be in place.

8. Install the aftercooler housing. Torque the bolts to required specs.

9. Install new O-rings on the 4N-1849 Coupling. Insert the coupling into the housing for the turbocharger air and the new 4N-8677 Outlet Pipe. Use plenty of lubrication for mobility.

10. Install the pipe assembly and the coupling assembly on the turbocharger cartridge. Tighten the four bolts on the aftercooler housing without the gasket in place.

11. Adjust the high temperature exhaust housing in order to benefit alignment of the housing on the turbocharger.

12. Line up the oil holes and tighten both of the clamps on the turbocharger.

13. Tighten the high temperature bolts on the 122-8433 Exhaust Elbow of the turbocharger.

14. Loosen the two clamps for the turbocharger cartridge. Readjust any tension out of the turbocharger. Tighten the two turbocharger clamps. Tighten the two bolts for the turbocharger oil lines.

15. Loosen the four bolts on the aftercooler housing. Insert the gasket for the aftercooler housing and check for clearance. Make sure that the face of the exhaust pipe is square to the housing. Ensure that the face of the outlet pipe and the housing is free of tension.

16. Torque the assemblies to the required specs.