INJECTOR GP-FUEL 3210990 - Caterpillar

SEBE7984-02 May 12, 2002
(Revised September 2003)
U-95
A-68
AU-64
S-64
H-63
O-81
Afterfailure only PRODUCT SUPPORT PROGRAM FOR REPAIRINGLEAKS BETWEEN THE TURBOCHARGER TURBINE HOUSING AND THE EXHAUST ELBOW ONCERTAIN 3508, 3512, AND 3516 ENGINES
1052 PS50433
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50433" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe May 12, 2002 (Revised October 2002) Service Letter. Changes have beenmade to the Termination Date and the Affected Product.TERMINATION DATE
December 31, 2003PROBLEM
Certain 3508, 3512, and 3516 turbocharger turbinehousing to exhaust elbow joints may leak exhaust in certain applications.AFFECTED PRODUCT
There are three different groups included in thisprogram. Group 1 includes engine configurations that have in-line turbochargersand 1240215 exhaust elbow. Group 2 includes engine configurations thathave in-line turbochargers and 1476618 exhaust elbow. Group 3 includesengine configurations that have off-set turbochargers and 1628864 exhaustelbow.
Model Identification Number
Group1
3508 9WN2-1596Y1509-20003HM2-143PS168-196
3508B 7SM28-535,537, 539-6003DM81-2642BM113-1663DW144-1625PS208-281BAG2-17CBB111-1641TW233-295
3512 66Z583-662,911 914
3512B 2GW216-3254AW384-388, 390-406, 413-420,423-441, 443-481, 483-484, 486, 488-500, 502-610, 612-649, 658-707
3512BM/ 1PW309-400
DV096 4DR1
Group 2
3512B 3ZW121-123,130-143, 146-151, 153-154, 156-157, 160-165, 167-168, 170-171, 175-177,182-186, 193-194, 197-207, 211-212, 216-219, 229-246, 248, 258, 260, 263-270,274-2848DF177-186
3512 3RS308,3093WS333
Group 3
3512B 2EZ215-2684TN253, 257, 260-261, 263, 265-266,269-277, 281-285, 287-449, 451-5177HM209-211, 214-218, 221-228,233-2342AF194-3058EM326-394, 396-398, 402BRC146-147PWG100-109
3516B 8KN382-386,400-407, 410-420, 425-429, 433, 435, 442-447, 449-454CBN256-262
3512BPU 6RZ357PARTS NEEDED
Group 116 - 6V6753 BOLT-HIGH TE
2 - 1419290 BELLOWS AS
4 - 2071354 GASKET-EXH MGroup 216 - 6V6753 BOLT-HIGH TE
2 - 1880468 BELLOWS AS
4 - 2071382 GASKET-EXHAUGroup 312 - 6V1943 BOLT-HIGH TE
8 - 6V6753 BOLT-HIGH TE
2 - 1880469 BELLOWS AS
4 - 2071382 GASKET-EXHAUACTION REQUIRED
See the attached Rework Procedure.SERVICE CLAIM ALLOWANCES
Component hours Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-3000 100% 3.0 0 0 0 0
3001-7000 50% 1.5 0 0 50% 1.5
7001-Up 0% 0 0 0 100% 3.0
This is a 3.0?hr job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Remove exhaust heat shield sections surroundingthe turbocharger.
Remove all the bolts that retain the half flangesin the turbine housing and the exhaust elbow.
Remove the half flanges.
Remove the bellows.
Remove the gaskets.
Clean the sealing surfaces on the half flanges,turbine housing and exhaust elbow.
Check the sealing surfaces for indications ofmaterial erosion.
If a component's sealing surfaces show erosionor are not flat, then that component must be replaced.
Install new gaskets.
Install new bellows.
Re-install half flanges, unless judged non-reusableas per step 8. If non-reusable, install new half flanges.
Install new bolts to retain the half flanges inthe turbine housing and the exhaust elbow. Anti-sieze must be used on thebolt threads and under head area.
Torque the bolts to 54 +/- 5 N m(40 +/- 4 lb-ft).
Install the exhaust heat shield sections surroundingthe turbocharger.
Do not re-install the fabricated metal shieldsthat cover the top of the turbine housing if the engine was so equipped(engines in group 1 and group 2). The part numbers of these shields are:1408937, 1408938, 1480842, 1480843, 1496511, 1496512, 1496513, and 1496514.These shields are no longer required and may contribute to improper bolttorque at the shield mounting location.