CONE-BEARING 1559432 - Caterpillar

SEBE7474
December 2, 2000
U-310
A-224
AU-184
S-144
H-111
O-254
before or
after failure PRODUCT SUPPORT PROGRAM FOR REPLACING THE AFTERCOOLER BALANCE TUBE O-RING SEALS ON CERTAIN 789C AND 793C OFF HIGHWAY TRUCKS AND ON CERTAIN 3516B ENGINES
1058 PS40424 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 "PS40424" 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.
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.
Termination Date
December 31, 2002
PROBLEM
The o-ring seals on the aftercooler air intake balance pipe may have been damaged on certain 3516B engines during the assembly process. Damaged o-rings seals may cause excessive black smoke and high exhaust temperatures resulting in poor engine performance. The o-rings seals will need to be replaced to ensure proper sealing.
AFFECTED PRODUCT
Model Identification Number
3516B 8NW234-246, 248-251, 256-259, 261
2JW278?286
6HN1026-1033, 1035-1036, 1038-1039, 1041-1042, 1044-1046, 1049-1054, 1056-1060, 1063-1070, 1072-1102, 1107-1117, 1119-1133, 1135-1204, 1206-1217, 1218-1220, 1222-1230, 1236, 1239-1240, 1242-1247, 1249, 1267, 1293-1296
7RN1493-1498, 1500-1501, 1503-1504, 1506-1507, 1510-1511, 1515, 1525-1526, 1528-1529, 1536, 1539-1540, 1551, 1555-1556, 1559-1561, 1563, 1566-1567, 1572-1574, 1577, 1581, 1599
789C 2BW306-312
793C ATY225
PARTS NEEDED
QTY Part Number Part Name
2 6V0973 Seal
1 1073758 Seal-Aftercooler
2 1097411 Seal - O-Ring
3 Meters 5P6025 Cable w/Rope
3 5P8940 Seal - O-Ring ACTION REQUIRED
See the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-99999 months 100 % 2 0 0 0 0
This is a 2-hour job.PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)
Rework Procedure
Location of the 5P8940 O-Ring Seals
The aftercooler balance pipe is located between the front and rear aftercooler air intake housings. See Illustration #1.
Illustration #1 - Location of Aftercooler Balance Pipe
There are three 5P8940 O-ring seals on the aftercooler balance pipe that need to be replaced. Two O-rings are located on the front of the pipe and one is located on the rear of the pipe. See Illustration #2 for location of the O-ring seals.
Illustration #2 - Location of 5P8940 O-ring Seals
Disassembly Procedure
Remove the two bolts that connect the turbo compressor housing to the aftercooler air intake housing cover for each of the rear two turbos. See Illustration #3.
Illustration #3 - Bolt Location
Remove the heat shields that cover the turbo inlet if present.
Loosen the band clamp between the turbo compressor housing and the bearing housing. Loosen the band clamps between the turbo intake and the air inlet pipe. Perform this step on both rear turbos. See Illustration #4.
Illustration #4 ? Band-Clamp Location
To aid in the rotation of the turbo compressor housing, slide the rubber boot between on the turbo inlet and air intake pipe toward the rear of then engine. See Illustration #4.
Rotate the compressor housing on the left rear turbo counterclockwise away from the aftercooler air intake housing cover.