2004/07/01 Caterpillar


Improved Turbocharger Water Lines are Used {1052, 1059, 1380}

Usage:

3516B 1NW
Engines:
3508 (S/N: 95Y1-UP; 3LS1-UP; 97Y1-UP; 23Z1-UP; 68Z1-UP; 70Z1-UP; CTF1-UP)
3508B (S/N: CBB1-UP; LPD1-UP; S2B1-UP; S2D1-UP; S2E1-UP; S2F1-UP; BAG1-UP; 2BM1-UP; 3DM1-UP; 7SM1-UP; 6PN1-UP; 5PS1-UP; 1TW1-UP; 2HW1-UP; 3DW1-UP; BPX1-UP)
3512 (S/N: 2WK1-UP; 3MS1-UP; 49Y1-UP; 24Z1-UP; 65Z1-UP; 67Z1-UP; CTE1-UP; 1KZ1-UP)
3512B (S/N: BRC1-UP; 2AF1-UP; 8DF1-UP; FFG1-UP; PWG1-UP; S2H1-UP; S2J1-UP; S2K1-UP; S2L1-UP; S2M1-UP; 7HM1-UP; 8EM1-UP; 8RM1-UP; BRN1-UP; S2N1-UP; 4TN1-UP; 1PW1-UP; 2GW1-UP; 3KD1-UP; 3ZW1-UP; 4AW1-UP; 5AW1-UP; 2EZ1-UP; CTB1-UP)
3516 (S/N: 71Z1-UP; 73Z1-UP)
3516B (S/N: CDE1-UP; CBN1-UP; 8KN1-UP; S2S1-UP; S2W1-UP; 1NW1-UP; 2FW1-UP; 3CW1-UP; CTA1-UP)

Improved turbocharger water lines are now used on the 3500 Engines that are listed above. The new lines offer improved flexibility and improved durability. The new turbocharger water lines are effective with the serial numbers that are listed in Table 1 and adaptable to the engines that are listed above. The previous lines were rigid steel lines that were not tolerant to misalignment or to vibration. The new flexible hose will be more tolerant to misalignment and to vibration.

Table 1
    Sales Model    
3508 3508B     3512     3512B     3516     3516B    
Serial Number Breaks     S/N:3LS228-UP     S/N:CBB232-UP     S/N:2WK87-UP     S/N:BRC159-UP     S/N:71Z406-UP     S/N:CDE313-UP    
S/N:95Y1235-UP S/N:S2B109-UP     S/N:3MS233-UP     S/N:2AF400-UP     S/N:73Z973-UP     S/N:CBN332-UP    
S/N:97Y748-UP S/N:LPD9-UP     S/N:49Y1054-UP     S/N:8DF187-UP         S/N:8KN586-UP    
S/N:23Z7948-UP S/N:S2D105-UP     S/N:24Z10164-UP     S/N:FFG227-UP         S/N:S2S120-UP    
S/N:68Z1266-UP S/N:S2E149-UP     S/N:65Z1152-UP     S/N:PWG121-UP         S/N:S2W102-UP    
S/N:70Z1079-UP S/N:S2F104-UP     S/N:67Z2098-UP     S/N:S2H113-UP         S/N:1NW145-UP    
S/N:CTF264-UP S/N:BAG25-UP     S/N:CTE363-UP     S/N:S2J122-UP         S/N:2FW343-UP    
S/N:2BM188-UP     S/N:1KZ1734-UP     S/N:S2K108-UP         S/N:3CW258-UP    
S/N:3DM482-UP         S/N:S2L161-UP         S/N:CTA153-UP    
S/N:7SM993-UP         S/N:S2M110-UP            
S/N:6PN889-UP         S/N:7HM269-UP            
S/N:5PS322-UP         S/N:8EM527-UP            
S/N:1TW361-UP         S/N:8RM760-UP            
S/N:2HW269-UP         S/N:BRN196-UP            
S/N:3DW180-UP         S/N:S2N107-UP            
S/N:BPX101-UP         S/N:4TN841-UP            
        S/N:1PW441-UP            
        S/N:2GW428-UP            
        S/N:3KD281-UP            
        S/N:3ZW585-UP            
        S/N:4AW884-UP            
        S/N:5AW137-UP            
        S/N:2EZ361-UP            
        S/N:CTB190-UP            

The affected water lines groups are listed in Table 2 and Table 3. Refer to Table 2 and Table 3 in order to find the parts that must be removed from each water lines group. Also, refer to Table 2 and Table 3 in order to find the parts that must be added for each water lines group.

The support brackets for the exhaust manifolds have also changed in order to adapt to the new water lines groups. New brackets for the exhaust manifolds are available, but new brackets are not mandatory. The previous brackets for the exhaust manifolds can be reused. The brackets can be adapted in order to accommodate the new water lines groups. One hole must be drilled in each of the brackets for the exhaust manifolds in order to accommodate a retaining clip for the new turbocharger water lines. Refer to Illustration 1 and Illustration 2.




Illustration 1g01068189

New 8N-8820 Bracket




Illustration 2g01068190

New 163-4270 Bracket As

116-9870 Water Lines Group

Table 2
116-9870 Water Lines Group    
Add     Remove    
Part     Qty     Part     Qty    
030-7948 Elbow     2     6V-8625 Elbow     2    
252-5658 Hose As     2     113-4645 Tube As     2    
4S-4869 Tee     1     6V-8775 Face Seal Tee     1    
0S-1591 Bolt     1            
0S-1594 Bolt     1            
9X-8606 Clip     2            
6V-8801 Nut     2            
6V-8397 O-Ring Seal     1            
5M-2894 Hard Washer     4            
9G-8140 Spacer     1            
        033-6033 O-Ring Seal     4    



Illustration 3g01072924

Previous 116-9870 Water Lines Group

(1) 6V-8775 Face Seal Tee

(2) 033-6033 O-Ring Seal

(3) 6V-8625 Elbow

(4) 113-4645 Tube As




Illustration 4g01072974

New 116-9870 Water Lines Group

(5) 252-5658 Hose As

(6) 0S-1591 Bolt

(7) 9X-8606 Clip

(8) 6V-8801 Nut

(9) 5M-2894 Hard Washer

(10) 9G-8140 Spacer

(11) 4S-4869 Tee

(12) 0S-1594 Bolt

(13) 6V-8397 O-Ring Seal

(14) 030-7948 Elbow

161-4087 Water Lines Group

Table 3
161-4087 Water Lines Group    
Add     Remove    
Part     Qty     Part     Qty    
8M-0505 Connector     2     2P-7636 Connector     2    
030-7948 Elbow     2     6V-8625 Elbow     2    
252-5658 Hose As     3     146-7639 Hose As     1    
113-4645 Tube As 1    
166-5935 Tube As 1    
4S-4869 Tee     1     6V-8775 Face Seal Tee     1    
0S-1594 Bolt     1            
0S-1591 Bolt     1            
9X-8606 Clip     2            
6V-8801 Nut     2            
5M-2894 Hard Washer     4            
9G-8140 Spacer     1            
        033-6033 O-Ring Seal     4    



Illustration 5g01072925

Previous 161-4087 Water Lines Group

(15) 033-6033 O-Ring Seal

(16) 2P-7636 Connector

(17) 6V-8625 Elbow

(18) 146-7639 Hose As

(19) 113-4645 Tube As

(20) 166-5935 Tube As

(21) 6V-8775 Face Seal Tee




Illustration 6g01072979

New 161-4087 Water Lines Group

(22) 252-5658 Hose As

(23) 0S-1591 Bolt

(24) 9X-8606 Clip

(25) 6V-8801 Nut

(26) 5M-2894 Hard Washer

(27) 9G-8140 Spacer

(28) 4S-4869 Tee

(29) 0S-1594 Bolt

(30) 8M-0505 Connector

(31) 030-7948 Elbow

Note: The 030-7948 Elbow that is mounted on the right side of the engine must be mounted at a 45 degree angle from the vertical position.

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