ROD AS 1344784 - Caterpillar

Caterpillar: Confidential Yellow
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.
This Program must be administered as soon as possible. When reporting the repair, use "PI3024" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3024" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Refer to your Warranty Bulletin for detailed information in regards to Product Improvement Programs.
Completion Date
January 31, 1998Termination Date
July 31, 1998Problem
The coolant flow through the water cooled center section of the turbochargers is very restrictive on the COSA dry manifold engines due to undersized supply lines. This could cause excessive temperature build up in the turbo housings and could result in the 7N7628 Turbo Housing Cover Gasket failures. These higher temperatures could also shorten turbo bearing life.
Affected Product
Model & Identification Number
G3512 (7NJ196-198, 7NJ208-211, 7NJ216, 7NJ217, 7NJ219, 7NJ221)
G3516 (4EK457, 4EK617, 4EK622, 4EK670, 4EK675, 4EK756, 4EK776, 4EK789, 4EK791, 4EK793 , 4EK795, 4EK840, 4EK841, 4EK843-846, 4EK850, 4EK857, 4EK863, 4EK864 , 4EK867, 4EK868, 4EK870, 4EK874-877, 4EK885, 4EK900, 4EK901, 4EK904 , 4EK906-908, 4EK910, 4EK912, 4EK920, 4EK923, 4EK926, 4EK928, 4EK933, 4EK934 , 4EK938, 4EK941, 4EK943-945, 4EK954, 4EK958, 4EK959, 4EK964, 4EK972-978 , 4EK984, 4EK989, 4EK996, 4EK997, 4EK1002-1005, 4EK1008-1013 , 4EK1016, 4EK1017, 4EK1031, 4EK1032, 4EK1034-1036, 4EK1041 , 4EK1056-1058, 4EK1062, 4EK1064, 4EK1080, 4EK1083, 4EK1090, 4EK1092 , 4EK1108-1111, 4EK1144, 4EK1146, 4EK1170, 4EK1214)
Parts Needed
2 - 7H7055 Clip2 - 8L2786 Seal-O-Ring2 - 8M0755 Connector2 - 2N1288 Elbow8 - 7N7628 Gasket2 - 1P1441 Nut-Flared1 - 5P7701 Seal1 - 6S2231 Cross-Flared2 - 6S5693 Tee-Swivel1 - 038581 Tee-Union1 - 307951 Elbow2 - 308110 Connector2 - 308144 Reducer-Flared2 - 619463 Connector-Flared1 - 1377394 Tube Assembly1 - 1409406 Tube Assembly1 - 1409407 Tube Assembly1 - 1409409 Tube Assembly1 - 1409410 Tube Assembly1 - 1409411 Tube Assembly1 - 1436857 Tube Assembly1 - 1436858 Tube AssemblyAction Required
1. Drain engine coolant.2. Remove the turbo water supply and the turbo and exhaust elbow water return lines. Remove all turbo housing covers and gasket material from the turbo bearing housings.3. Install the new turbo water supply and the turbo and exhaust elbow water return lines, as shown in Illustration 1. Replace all turbo covers using new 7N7628 Gaskets.4. Refill cooling system with coolant.
Illustration 1Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
This is a 6-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)Copy Of Owner Notification For U.S. And Canadian Owners