Increased Coolant Flow To Turbocharger Cartridges On Certain G3512 And G3516 Engines Caterpillar

Increased Coolant Flow To Turbocharger Cartridges On Certain G3512 And G3516 Engines

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Caterpillar: Confidential Yellow

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.

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3024" as the Part Number, "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 "PI3024" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: Refer to your Warranty Bulletin for detailed information in regards to Product Improvement Programs.

Completion Date

January 31, 1998

Termination Date

July 31, 1998

Problem

The coolant flow through the water cooled center section of the turbochargers is very restrictive on the COSA dry manifold engines due to undersized supply lines. This could cause excessive temperature build up in the turbo housings and could result in the 7N7628 Turbo Housing Cover Gasket failures. These higher temperatures could also shorten turbo bearing life.

Affected Product
Model & Identification Number

G3512 (7NJ196-198, 7NJ208-211, 7NJ216, 7NJ217, 7NJ219, 7NJ221)

G3516 (4EK457, 4EK617, 4EK622, 4EK670, 4EK675, 4EK756, 4EK776, 4EK789, 4EK791, 4EK793 , 4EK795, 4EK840, 4EK841, 4EK843-846, 4EK850, 4EK857, 4EK863, 4EK864 , 4EK867, 4EK868, 4EK870, 4EK874-877, 4EK885, 4EK900, 4EK901, 4EK904 , 4EK906-908, 4EK910, 4EK912, 4EK920, 4EK923, 4EK926, 4EK928, 4EK933, 4EK934 , 4EK938, 4EK941, 4EK943-945, 4EK954, 4EK958, 4EK959, 4EK964, 4EK972-978 , 4EK984, 4EK989, 4EK996, 4EK997, 4EK1002-1005, 4EK1008-1013 , 4EK1016, 4EK1017, 4EK1031, 4EK1032, 4EK1034-1036, 4EK1041 , 4EK1056-1058, 4EK1062, 4EK1064, 4EK1080, 4EK1083, 4EK1090, 4EK1092 , 4EK1108-1111, 4EK1144, 4EK1146, 4EK1170, 4EK1214)

Parts Needed

2 - 7H7055 Clip

2 - 8L2786 Seal-O-Ring

2 - 8M0755 Connector

2 - 2N1288 Elbow

8 - 7N7628 Gasket

2 - 1P1441 Nut-Flared

1 - 5P7701 Seal

1 - 6S2231 Cross-Flared

2 - 6S5693 Tee-Swivel

1 - 038581 Tee-Union

1 - 307951 Elbow

2 - 308110 Connector

2 - 308144 Reducer-Flared

2 - 619463 Connector-Flared

1 - 1377394 Tube Assembly

1 - 1409406 Tube Assembly

1 - 1409407 Tube Assembly

1 - 1409409 Tube Assembly

1 - 1409410 Tube Assembly

1 - 1409411 Tube Assembly

1 - 1436857 Tube Assembly

1 - 1436858 Tube Assembly

Action Required

1. Drain engine coolant.

2. Remove the turbo water supply and the turbo and exhaust elbow water return lines. Remove all turbo housing covers and gasket material from the turbo bearing housings.

3. Install the new turbo water supply and the turbo and exhaust elbow water return lines, as shown in Illustration 1. Replace all turbo covers using new 7N7628 Gaskets.

4. Refill cooling system with coolant.

Illustration 1