Early Hour Turbocharger Failures On Certain 3116 Marine Engines Caterpillar

Early Hour Turbocharger Failures On Certain 3116 Marine Engines

July 14, 1997
U-199
A-172
AU-156
S-93
H-49.2
O-170
TM-7

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 "PI3026" 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 "PI3026" 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.

NOTE: If this rework has been completed under a previous Service Letter Program, do not administer this Program. Indicate in the SIMS Report that the work has been completed under another Program and list the program number.

Completion Date

Termination Date

Problem

Early hour turbocharger failure may occur on certain engines equipped with a 1305899 Air Cleaner Mounting Bracket released for use with 1305921 and 1277077 Turbochargers having the four inch diameter compressor inlet hose and the standard air cleaner mounting group.

Affected Product
Model & Identification Number

3116 (4KG3214-5038) (If engine was reworked with a 1305899 Air Cleaner Bracket), (1SK1163-1597) (If engine was reworked with a 1305899 Air Cleaner Bracket)

3116 (4KG5039-6319) (Engines built with 1305899 Bracket), (1SK1598-1947) (Engines built with 1305899 Bracket)

3116 (4KG6320-6466) (Engines built with 1434049 Bracket)

NOTE: The Affected Product includes engines that were originally built with, or retrofitted with, a Air Cleaner Bracket. It can be identified by the following:

- It has four straps that fit inside the air cleaner element to support the air cleaner mounting stud.

- The hose from the adapter to the cold housing of the turbocharger has a four inch diameter on BOTH ends. This adapter was intended for use with 1305921 or 1277077 Turbochargers that have the 1305922 cold housing with the four inch inlet diameter. There is a similar bracket on earlier built engines that has a 4.0 to 2.75 inch reducer hose from the adapter to the cold housing that is NOT a problem, and this PSP is not adaptable to those engines.

The affected product also includes engines built with the 1434049 Bracket which is similar to the 1305899 Bracket with the straps removed, but does not have the longer flared inlet tube like the new 1448883/">1448883.

Parts Needed

NOTE: Do NOT order parts for this program if parts have been ordered under PS8950 dated March 23, 1997.

4C4030 Loctite

1 - 8N5001 Bolt

1 - 1S7104 Seal-O-Ring

2 - 8T4224 Washer

2 - 8T4908 Bolt

1 - 7W5040 Element

2 - 7XO613 Washer

1 - 1163359 Retainer

1 - 1434048 Bracket Assembly

1 - 1448883 Bracket Assembly

NOTE: On 4KG6320-6466, only the 1448883 Bracket and 7W5040 Element is needed.

Turbocharger Replacement- (After Failure Only)

1 - 7C7613 Gasket

1 - 9M4849 Seal-O-Ring

1 - 4P7704 Gasket

1 - 1S7057 Gasket

1 - 7W2398 Gasket

1 - OR7212 Turbo Group

Action Required

See the attached rework procedure.

Owner Notification

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

Service Claim Allowances

NOTE: Allow up to 0.5 hours for inspection of adapter, 1.5 hours for the inspection and replacement of the air cleaner mounting, and up to 4.5 hours for the turbocharger replacement.

Parts Disposition

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

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

Attach.

(1-Owner Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

1. Inspect the engine to determine if it has the 1305899 or 1434049 Air Cleaner Mounting Bracket. Engines equipped with AirSep air cleaners do not use this bracket and should NOT be reworked before failure.

2. If the engine has the 1305899 or 1434049 Air Cleaner Mounting Bracket, remove the bracket and the air cleaner element.

3. Install the new air cleaner mounting group and a new air cleaner element.

NOTE: Engines with the 1434049 Bracket can use the 1448883 Bracket as a direct replacement. Other mounting group parts will already be on the engine.

Replacement of Turbocharger After Failure Only

If a turbocharger fails on any affected engine, rework that engine with the new OR7212 Turbocharger and open center flared inlet air cleaner mounting. Engines with AirSep or those previously reworked with the new air cleaner mounting would only need the new turbocharger.

NOTE: If the compressor wheel has failed on ANY turbocharger, thoroughly clean the debris from inside the aftercooler housing and replace the air cleaner element (Standard foam air cleaner element is 7W5040, AirSep element is 4P7918).

NOTE: If the turbocharger fails on one engine in a dual powered boat, update BOTH engines with the new open center mounting and turbocharger. If the engine has previously been updated with the new air cleaner group, OR if it is equipped with AirSeps, it would only need the new turbocharger.

Illustration 1