SEAL-O-RING 3S1219 - Caterpillar

Engine: G3516C (S/N: GSB1-UP; TJB1-UP; GZZ1-UP; RWA1-UP; DKR1-UP) G3516E (S/N: GAS1-UP; SLY1-UP) G3520C (S/N: MAD1-UP; GZJ1-UP; GZK1-UP; GZL1-UP; GZM1-UP; GZN1-UP; B9P1-UP; HAT1-UP; CWW1-UP; CWY1-UP; GDB1-UP; GHC1-UP; GHE1-UP; JBX1-UP; JBZ1-UP) G3520E (S/N: GZG1-UP; GZH1-UP; HAL1-UP; SXY1-UP; GHM1-UP; GHR1-UP)Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Illustration 1 g01350357
Point (A) is lower than point (B). This condition is an example of vertical misalignment. (1) Inlet for turbocharger (2) Elbow of the exhaust manifold on the right side of the engine
Illustration 2 g01350358
Bottom viewPoint (B) is closer to the rear of the engine than point (A). This is an example of horizontal misalignment. (1) Inlet for turbocharger (2) Elbow of the exhaust manifold on the right side of the engineThe capability of the bellows in the exhaust manifold to correct misalignment of the exhaust manifold is being exceeded because of movement in the exhaust manifold. The misalignment occurs between the exhaust manifold elbow and the elbow for the turbocharger inlet. Both vertical misalignment and horizontal misalignment can occur. Vertical misalignment occurs when the exhaust manifold elbow is higher or lower than the elbow for the turbocharger inlet. Refer to Illustration 1. Horizontal misalignment occurs when the exhaust manifold elbow is further forward than the elbow for the turbocharger inlet. Refer to Illustration 2.This condition will cause the inner liner of the bellows to contact the inside of the bellows. If the engine is allowed to continue operating in this condition, vibration will cause the liner to rub a hole into the bellows. This will result in an exhaust leak that will cause low power and unscheduled downtime. Solution
Perform this procedure if any of the following situations occur.
Failure of the exhaust bellows
Before a new exhaust bellows is installed
When a misalignment is noticed
Remove the 227-9027 Bellows As from the side that will be realigned.
Illustration 3 g01350360
Top-front view (2) Elbow of the exhaust manifold on the right side of the engine (3) Support bracket (4) Bolts
Loosen bolts (4) that connect elbow (2) to support bracket (3) .
Illustration 4 g01350359
Left side view (5) Bolts
Loosen bolts (5) that secure the exhaust manifold to the number 1 cylinder head that is on the right side or to the number 2 cylinder head that is on the left side. Refer to illustration 4.
Align the centerline of the large elbow with the centerline of the elbow for the turbocharger inlet.The elbows must be aligned horizontally. The elbows must be aligned vertically.
Reinstall bolts (4) and support bracket (3) .
Tighten bolts (4) and (5) .
Install the new 227-9027 Bellows As .
Tighten the clamps.
Tighten the clamps to 25 6 N m (19 5 lb ft).
Tap around the clamps with a soft faced hammer.
Tighten the clamps again to 25 6 N m (19 5 lb ft).
Verify that the alignment of the bellows is correct.