PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPAIRING THE CONTACT BETWEEN THE TURBOCHARGER COMPRESSOR HOUSING AND THE COMPRESSOR WHEEL ON CERTAIN 3516B GENERATOR SET ENGINES

Usage:

Caterpillar: Confidential Yellow

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPAIRING THE CONTACT BETWEEN THE TURBOCHARGER COMPRESSOR HOUSING AND THE COMPRESSOR WHEEL ON CERTAIN 3516B GENERATOR SET ENGINES

SEBE7960-03

April 7, 2002
(Revised May 2002)
U-76
A-56
AU-49
S-49
H-49
O-64

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPAIRING THE CONTACT BETWEEN THE TURBOCHARGER COMPRESSOR HOUSING AND THE COMPRESSOR WHEEL ON CERTAIN 3516B GENERATOR SET ENGINES
1052		PS40913

NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS40913" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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 Revised Service Letter replaces the April 7, 2002 (Revised April 2002) Service Letter. Changes have been made to the Affected Product.

TERMINATION DATE

April 30, 2003

PROBLEM

Some 1800 Rpm 3516B Generator Set Engines with a rating of 1825ekw and higher, may fail the turbocharger due to contact between the turbocharger compressor housing and compressor wheel. Turbos on the engines listed below may need to be inspected as per the attached rework procedure. Based upon the results of their inspection, some turbos and air pipes may need to be replaced.

AFFECTED PRODUCT

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Model

Identification Number

3516B

BPD143-156, 179-216, 223-232, 234-236, 238-307, 310-325, 327, 333-334, 336, 338-339, 341-346, 348-350, 352, 354, 356-358, 360-366, 369, 376, 380-383, 385, 387-391, 393-395, 397-410, 413-414, 417-418, 420-423, 425-426, 428-430, 432-439, 441, 444-448, 450, 454-456, 460, 462-463, 465, 467-472, 474-475, 478-488, 491-493, 495, 497-500, 503-507, 512, 515-516, 520-525, 527, 531, 537, 544-545, 549-551, 553, 556-558, 560, 562-563, 567-568, 571-575, 578, 580-581, 586-587, 589, 594-596, 602-605, 607-608, 612, 614-615, 624-625, 628, 631-641, 643, 645, 649, 651, 653-654, 656-657, 661, 670, 680-682, 697, 705, 711, 747-748

FDN111, 113, 117-118, 121-124, 126, 128, 130, 138-169, 173, 177-179, 181, 196-210, 212, 214, 215, 219, 223, 228, 229, 232, 233, 235, 236, 241, 244-247, 249, 250, 251, 253, 257, 258, 267, 269, 270, 272-274, 276, 277, 279-281, 283-321, 307-308, 322-324, 327, 329-334, 336-340, 343-361, 363-366, 368-374, 375-392, 395-397, 400, 405-407, 409-419, 425, 426, 434, 445, 446, 465

6HN01254, 1256, 1259, 1263, 1265, 1269, 1284, 1288-1289, 1293, 1295-1297, 1300-1305, 1307-1310, 1312-1316, 1318, 1321-1326, 1329-1332, 1334, 1337, 1340, 1343, 1345, 1349-1362, 1365-1366, 1369-1371, 1373-1378, 1381, 1383, 1385-1394, 1396, 1398-1402, 1404, 1407, 1410-1411, 1413, 1419-1422, 1429, 1432, 1434-1435, 1437, 1443, 1446, 1448-1450, 1452-1454, 1457-1458, 1463-1464, 1466-1467, 1469, 1471, 1473-1475, 1479-1480, 1485-1487, 1491, 1497, 1512-1513, 1515-1516, 1519, 1526, 1528, 1530-1531, 1533, 1535-1536, 1538, 1541-1543, 1545-1546, 1548, 1550, 1554-1564, 1566, 1570-1571, 1573-1576, 1578-1579, 1581, 1584-1586, 1593-1594, 1596-1599, 1602-1610, 1612-1613, 1621, 1624-1625, 1627, 1629, 1637, 1639, 1641, 1644, 1646, 1648, 1654, 1656-1658, 1668, 1671, 1677-1680, 1682-1683, 1690, 1696-1697, 1703-1707, 1709-1714

7RN01342, 1348-1352, 1354-1356, 1358, 1360, 1363-1364, 1369-1371, 1373-1377, 1379-1380, 1382-1391, 1393-1394, 1396, 1398, 1400, 1402, 1405-1406, 1408, 1410-1419, 1421-1424, 1426, 1428-1429, 1431-1436, 1440-1443, 1445, 1447, 1449-1461, 1463-1464, 1466, 1468-1469, 1474, 1476-1479, 1481-1487, 1489-1490, 1492, 1499, 1502, 1504-1505, 1508-1519, 1521-1527, 1529-1535, 1537-1538, 1541-1550, 1552-1559, 1561-1569, 1571, 1575-1578, 1580-1581, 1583-1589, 1592-1603, 1605-1615, 1617-1626, 1628-1631, 1634-1638, 1641-1642, 1644-1646, 1649-1651, 1653-1664, 1666, 1668-1672, 1674-1676, 1678-1679, 1681-1683, 1686, 1690-1692, 1697-1699, 1704-1705, 1714-1715, 1719, 1721-1724, 1726-1730, 1744-1746, 1749-1751, 1753-1755, 1757-1763, 1765-1768, 1773-1784, 1786-1787, 1790, 1793-1796, 1799-1800, 1803-1812, 1817-1819, 1824-1828, 1830, 1833, 1836, 1838, 1840-1843, 1854, 1856-1861, 1863, 1865, 1867, 1871-1874, 1876-1878, 1880, 1882-1883, 1886-1887, 1901

PARTS NEEDED

NOTE: Parts will only be needed if the rework procedure needs to go beyond step four. Read the attached rework procedure before ordering any parts. 1 - 2172083 GASKET KIT
4 - 1467383 FLANGE
2 - 1550540 ELBOW-AIR IN
2 - 1550541 ELBOW-AIR IN
2 - 1550544 ELBOW
2 - 1550545 ELBOW
4 - 1566261 BRACKET
1 ? 10R0435 TURBO GP
8 - 7W3145 PLATE
8 - 0S1594 BOLT
4 - 0S1619 BOLT
4 - 0T0573 BOLT
4 - 1A2029 BOLT
4 - 5D5957 O-RING
8 - 8T6764 PIPE PLUG
4 - 9X6458 WASHER
16 - 5M2894 WASHER
16 - 6V3917 O-RINGS

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-100hrs	100%	*	0	0	0	0
NOTE: Inspection only - This is a 3.0?hr job. Inspect & Rework -* This is a 10.0?hr job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

No inspection or rework is required if engine service hours are greater than 100 hours and/or principal work code is something other than C70, C71, C72, C77, or C80.

If Service Hours are less than 100 hours and principal work code is C70, C71, C72, C77, or C80 then:

Loosen candy cane style inlet air tubes and roll them up and away from compressor housings to gain visibility of the turbo compressor wheel.
Carefully clean the oil tracks off of the turbo compressor housing around the compressor wheel.
Examine the turbo compressor housing and compressor wheel for rubbing.
If there is no sign of rubbing, reinstall the candy cane air tubes. No further action is needed.
If the compressor wheel has rubbed the compressor housing and the contacted area can?t be polished out with light polishing effort using emory paper, then replace the turbocharger.
If a burr can be detected with the fingernail, on the edge of the compressor wheel fin(s) that contacted the compressor housing, then replace the turbocharger.
If it is necessary to replace any one of turbochargers, remove and replace the air pipes between all four turbocharger compressor housings and aftercooler housings with the air pipe components listed.
If any one of the air pipes are replaced as per step 7, then replace all four air pipe sets for a given engine.
Replacement of any turbo should only occur based on the above inspection. Replacing one turbo on the engine does not require automatic replacement of the remaining turbos on the same engine. Exsisting turbos have the same performance as the replacements.