PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER COMPRESSOR OUTLET PIPING AND SEALS ON CERTAIN G3516E, 3520C, AND 3520E GENERATOR SET ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER COMPRESSOR OUTLET PIPING AND SEALS ON CERTAIN G3516E, 3520C, AND 3520E GENERATOR SET ENGINES

Usage:

REBE6543-02

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17Dec2010

(Revised 06Jan2011)

U-507

D-445

O-445

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER COMPRESSOR OUTLET PIPING AND SEALS ON CERTAIN G3516E, 3520C, AND 3520E GENERATOR SET ENGINES
1071		PS51946

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51946" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 17Dec2010 (Revised 05Jan2011) Service Letter. Changes have been made to Title and Parts Needed to change the quantity of 3607990/">360-7990 gaskets required from 2 to 1.

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TERMINATION DATE

31Dec2012

PROBLEM

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The existing turbocharger compressor outlet seals can fail leading to a boost leak on certain G3516E, 3520C, and 3520E Generator Set Engines.

AFFECTED PRODUCT

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Model	Identification Number
G3516E	GAS00111-00269 SLY00106-00109
G3520C	CWW00100
G3520E	GZG00111 GZH00111-00159 HAL00100-00102 SXY00100-00102

PARTS NEEDED

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Qty	Part Number	Description
8	1A1460	BOLT
8	1A5822	BOLT
32	1F7958	NUT-FULL
60	5P8245	WASHER-HARD
6	5P8247	WASHER-HARD
6	8S2331	BOLT-12 POINT HD
6	9S8004	PLUG-STOR
4	9X6458	WASHER-HARD
16	9X8874	BOLT
4	1984767	WASHER-HARD
6	2147568	SEAL-O-RING-STOR
4	2279011	GASKET
2	3442461	BELLOWS AS
1	3451039	ELBOW
1	3451040	ELBOW
1	3512801	BRACKET AS
1	3512802	BRACKET AS
1	3600416	HOUSING
1	3607989	GASKET
1	3607990	GASKET
2	3609687	GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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If a boost leak is found at the joints of the compressor outlet pipes, the complete air lines group from the compressor outlet to the throttle must be removed and replaced with new bellows, elbows, and adapter. Refer to Image 1 and the attached Rework Procedure for details.

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Image1

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%
0-80000 hrs, 0-120 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 4.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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Note: All fittings should be kept loose until all parts are installed. Final torque of each bolt should be started at the turbo compressor outlet flange with the support bracket bolts on the front housing being last. All bolts should be tightened to standard torque.

1) Remove the turbo compressor outlet piping and throttle inlet Y adapter. Refer to the disassembly and assembly manual for removal.

2) Rotate the left side turbo compressor outlet to 60 degrees from horizontal. Refer to Image 1.2.1. The right turbo compressor outlet should be at 41.5 degrees from horizontal and should not have to be adjusted. Image 1.2.2 is the right turbo.

Image1.2.1

Image1.2.2

3) Install the 351-2801 (left) and 351-2802 (right) Brackets to the front housing of the engine. Use four 0S-1571 Bolts and four 9X-6458 Washers.

4) Install the 360-0416 Housing (Y adapter) to throttle using six 8S-2331 Bolts, six 5P-8247 Washers, and a 3607990/">360-7990 Gasket.

5) Connect the 345-1040 Elbow to the left side and the 345-1039 Elbow to the right side of the 360-0416 Housing using eight 9X-8874 Bolts, eight 1F-7958 Nuts, eight 5P-8245 Washers, and a 360-9687 Gasket for each elbow.

6) Install the two 9S-8004 Plugs and two 214-7568 O-Rings in the 345-1039 Elbow and the 345-1040 Elbow.

7) Install the 344-2461 Bellow on to the turbo compressor outlet flange. Note the flow direction on the inlet flange of the bellow. On the top flange use four 1A-5822 Bolts, four 1F-7958 Nuts, two 198-4767 Washers and eight 5P-8245 Washers for the bellow, gasket and elbow connection.

On the bottom flange use four 1A-1460 Bolts, four 1F-7958 Nuts, and eight 5P-8245 Washers on the bellow, bracket, gasket, and turbo compressor outlet flange connection. A 227-9011 Gasket should be used on each side of the bellow. All hardware should be hand tightened only at this time.

Image1.3.1

8) Re-install the 226-7484 Tube Assembly and hardware with a new 360-7989 Gasket in place of the old 131-3718 O-Ring.

Image1.4.1

9) Tighten all fasteners to standard torque. Start at the turbo compressor outlet flange with the support bracket bolts on the front housing being last.

Refer to Image 1.5.1 for final installation.