TUBE AS-REFRIGERANT ORIFICE 7X2049 - Caterpillar

REBE6543-02
17Dec2010
(Revised 06Jan2011)
U-507
D-445
O-445
After Failure Only
PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER COMPRESSOR OUTLET PIPING AND SEALS ON CERTAIN G3516E, 3520C, AND 3520E GENERATOR SET ENGINES
1071 PS51946
This Program can only be administered after a failure occurs.The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51946" as the Part Numberand "7755" as the Group Number. 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.
This Revised Service Letter replaces the 17Dec2010 (Revised 05Jan2011) Service Letter. Changes have been made to Title and Parts Needed to change the quantity of 3607990/">360-7990 gaskets required from 2 to 1.
TERMINATION DATE
31Dec2012
PROBLEM
The existing turbocharger compressor outlet seals can fail leading to a boost leak on certain G3516E, 3520C, and 3520E Generator Set Engines.
AFFECTED PRODUCT
Model Identification Number
G3516E GAS00111-00269
SLY00106-00109
G3520C CWW00100
G3520E GZG00111
GZH00111-00159
HAL00100-00102
SXY00100-00102
PARTS NEEDED
Qty
Part Number Description
8 1A1460 BOLT
8 1A5822 BOLT
32 1F7958 NUT-FULL
60 5P8245 WASHER-HARD
6 5P8247 WASHER-HARD
6 8S2331 BOLT-12 POINT HD
6 9S8004 PLUG-STOR
4 9X6458 WASHER-HARD
16 9X8874 BOLT
4 1984767 WASHER-HARD
6 2147568 SEAL-O-RING-STOR
4 2279011 GASKET
2 3442461 BELLOWS AS
1 3451039 ELBOW
1 3451040 ELBOW
1 3512801 BRACKET AS
1 3512802 BRACKET AS
1 3600416 HOUSING
1 3607989 GASKET
1 3607990 GASKET
2 3609687 GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
If a boost leak is found at the joints of the compressor outlet pipes, the complete air lines group from the compressor outlet to the throttle must be removed and replaced with new bellows, elbows, and adapter. Refer to Image 1 and the attached Rework Procedure for details.
Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-80000 hrs,
0-120 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Note: All fittings should be kept loose until all parts are installed. Final torque of each bolt should be started at the turbo compressor outlet flange with the support bracket bolts on the front housing being last. All bolts should be tightened to standard torque.
1) Remove the turbo compressor outlet piping and throttle inlet Y adapter. Refer to the disassembly and assembly manual for removal.
2) Rotate the left side turbo compressor outlet to 60 degrees from horizontal. Refer to Image 1.2.1. The right turbo compressor outlet should be at 41.5 degrees from horizontal and should not have to be adjusted. Image 1.2.2 is the right turbo.
Image1.2.1
Image1.2.2
3) Install the 351-2801 (left) and 351-2802 (right) Brackets to the front housing of the engine. Use four 0S-1571 Bolts and four 9X-6458 Washers.
4) Install the 360-0416 Housing (Y adapter) to throttle using six 8S-2331 Bolts, six 5P-8247 Washers, and a 3607990/">360-7990 Gasket.
5) Connect the 345-1040 Elbow to the left side and the 345-1039 Elbow to the right side of the 360-0416 Housing using eight 9X-8874 Bolts,