Product Support Program For Installing Turbocharger Improvements On Certain 3508, 3512, And 3516 Generator Set Engines Rated For 50HZ (1500 RPM) Caterpillar

Product Support Program For Installing Turbocharger Improvements On Certain 3508, 3512, And 3516 Generator Set Engines Rated For 50HZ (1500 RPM)

Usage:

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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 can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4700" 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.

Termination Date

July 31, 1993

Problem

Certain high rated 3508, 3512, and 3516 Generator Set Engines rated for 50HZ (1500 rpm) may have poor exhaust valve service life if used in an application where the engine is operated for long periods of time at heavy loads. Different nozzles or turbine housings may be installed in the turbochargers to increase inlet manifold pressure and lower exhaust manifold temperature. The lower exhaust temperature will increase the service life of the valves.

Affected Product
Model & Identification Number & Arrangement Number

3508 (23Z1023-3952^*) 2W8406^*

3512 (24Z1317-4122^*) 2W8405^*

3516 (25Z684-2361^*) 2W8404^*

^*Applies only to continuous and prime power generator set engines with the engine arrangements shown. Not applicable for marine auxiliary generator set engines or other generator set engines which have water cooled exhaust manifold and water cooled turbocharger turbine housings.

NOTE: Some engines with higher ratings may require a change to maximum altitude limits with the new turbochargers. See engine performance specifications in the TMI Data System.

Parts Needed

Before Failure (3508 Engines)

2 - 7M7273 Gasket

8 - 2N2765 Bolt (If needed)

8 - 2N2766 Nut (If needed)

2 -7N6375 Turbine Housing

Before Failure (3512 Engines)

2 - 7M7273 Gasket

2 - 1N3086 Turbine Housing

8 - 2N2765 Bolt (If needed)

8 - 2N2766 Nut (If needed)

Before Failure (3516 Engines)

8 - 6V4605 Nut (If needed)

8 - 6V4606 Bolt (If needed)

2 - 1W5505 Gasket

2 - 4W9132 Turbocharger Nozzle

After Failure (3508 Engines)

1- 8C6977 Gasket Kit

16 - 7E4609 Exhaust Valve

16 - 7E4609 Inlet Valve (As required. See Note.)

16 - 7E5862 Inlet Valve Insert (As required. See Note.)

2- 7M7273 Gasket

8- 2N2765 Bolt (If needed)

8- 2N2766 Nut (If needed)

32 - 7N1819 Guide (As Required. See Note.)

2- 7N6375 Turbine Housing

16 - 1W1801 Exhaust Valve Insert

After Failure (3512 Engines)

24 - 7E4609 Exhaust Valve

24 - 7E4609 Inlet Valve (As required. See Note.)

24 - 7E5862 Inlet Valve Insert (As required. See Note.)

2- 7M7273 Gasket

2- 1N3086 Turbine Housing

8- 2N2765 Bolt (If needed)

8- 2N2766 Nut (If needed)

48 - 7N1819 Guide (As Required. See Note.)

1- 8T8184 Gasket Kit

24 - 1W1801 Exhaust Valve Insert

After Failure (3516 Engines)

1- 8C4377 Gasket Kit

32 - 7E4609 Exhaust Valve

32 - 7E4609 Inlet Valve (As required. See Note.)

32 - 7E5862 Inlet Valve Insert (As required. See Note.)

64 - 7N1819 Guide (As Required. See Note.)

8- 6V4605 Nut (If needed)

8- 6V4606 Bolt (If needed)

32 - 1W1801 Exhaust Valve Insert

2- 1W5505 Gasket

2- 4W9132 Turbocharger Nozzle

NOTE: Inspect, grind, and reuse inlet valves and seat inserts as much as possible. If not previously updated to the wider inlet valve insert according to the Service Letter dated June 12, 1990 - PS0446, the following engines may need to have cylinder head inlet valve insert bores machined and all 7E5862 Inserts installed: 23Z1023-2917, 24Z1317-3070, 25Z684-1818. Install non-counterbored valve guides on 23Z2918-3952, 24Z3071-4122, 25Z1819-2361, and earlier if counterbored valve guides have been installed previously.

Action Required

Before Failure

Follow the procedures in the Service Manual to replace the turbocharger parts. Install the new parts as required.

After Failure

Follow the procedures in the Service Manual to remove and disassemble the turbocharger and cylinder heads. Install the new parts as required.

Service Claim Allowances

NOTE: If there has been a previous repair or engine overhaul in which the customer participated, part age will apply. retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.

NOTE: An additional .5 hours per cylinder will be allowed to machine the inlet valve insert bores if the engine does not have the wider inlet valve seats. Machine the inlet valve seat counterbore to 60.508 ± 0.025 mm (2.3822 ± .0010").