PSP FOR TURBOCHARGER SURGE AND HIGH EXHAUST TEMPERATURE PROBLEMS ON CERTAIN 3508 GENERATOR SET ENGINES - MAILED US AND CAN ADA, CACO, COFA, LIMITED COSA - REVISED 1/89 Caterpillar

(Revised January 1989)
U-39
A-22
AU-24
E-21
O-25.2
1059   PS4197
NOTE: This Program can be administered either before or after a
failure. In either case the decision whether to apply the
Program is made by the dealer. When reporting the repair,
use "PS4197" as Part Number and "7755" as Group Number.
NOTE: This Revised Service Letter replaces the March 9, 1988
Service Letter. Changes have been made to the Affected
Product and to the Termination Date.

January 31, 1990

Only the higher rated 50Hz/60Hz prime power and standby 3508 Generator
Set Engines are affected. The specific serial numbers are shown below.
The Affected Products experience turbocharger surge problems while
operating near full load or when accepting large block loading. The
turbocharger surge is caused by uneven firing pulses in the two
exhaust manifolds. Some of the engines listed below have one or two tubes
connecting the inlet manifold to the exhaust elbow to minimize
turbocharger surge. However, the addition of the tube(s) may result in
high exhaust temperatures at rated or near rated loads.
The elimination of these tubes and the addition of the new exhaust
manifold parts will even out the firing pulses, eliminate the
turbocharger surge and reduce exhaust temperatures to acceptable levels
on these engines.

Model Identification Number
3508 23Z1180, 1181, 1183, 1191, 1200, 1204, 1205, 1211,
1215, 1217, 1221-1223, 1230, 1236, 1238, 1242,
1246 - 1250, 1256, 1257, 1261, 1267, 1269, 1277, 1278, 1280,
1281, 1283, 1290, 1291, 1298, 1310, 1311, 1313, 1314, 1325,
1328, 1330, 1339, 1341, 1342, 1347-1349, 1355, 1357, 1359,
1361-1363, 1366, 1371, 1374, 1375, 1380-1385, 1387, 1392, 1398,
1410, 1411, 1414, 1416, 1417, 1421, 1423, 1431, 1437, 1442,
1443, 1448-1450, 1452, 1457, 1459, 1464-1467, 1470, 1473, 1475,
1476, 1482, 1494, 1497, 1501-1503, 1507, 1516, 1530, 1533, 1535,
1536, 1538, 1539, 1547, 1549, 1550, 1553, 1558, 1565, 1566,
1568, 1570, 1574, 1589, 1591, 1594, 1598, 1600, 1601, 1603,
1606, 1608, 1610, 1611, 1619, 1625, 1626, 1630, 1637, 1645,
1652, 1657, 1660-1662, 1664, 1665, 1669, 1671, 1672, 1674,
1676, 1677, 1680, 1682-1686, 1691-1693, 1699, 1703, 1704,
1709, 1714, 1716, 1717, 1720, 1728-1731, 1740, 1741, 1744,
1747, 1748, 1754, 1755, 1758, 1767-1769, 1773, 1779, 1780,
1781, 1787, 1788, 1790, 1792, 1804, 1805, 1807, 1810, 1812,
1814, 1816, 1818-1820, 1824, 1825, 1827-1829, 1833, 1838, 1840,
1841, 1843-1845, 1849, 1850, 1853, 1856-1860, 1862, 1863, 1873,
1874, 1876, 1882-1885, 1887, 1888, 1899, 1990, 1906-1909, 1915,
1917, 1919-1921, 1924, 1925, 1927-1929, 1933, 1940, 1942, 1955,
1956, 1958, 1961, 1969, 1977, 1985, 1987, 1990, 1996, 2000,
2002-2004, 2015, 2017,
2018, 2020, 2033, 2035, 2054, 2055, 2069, 2074, 2084, 2090,
2110, 2118, 2129, 2135, 2137, 2138, 2140-2142, 2152, 2153,
2155-2157, 2160, 2164, 2169, 2172, 2187, 2190, 2191, 2195,
2198, 2207, 2208, 2212, 2213, 2223, 2226, 2227, 2252, 2257,
2260, 2266, 2270, 2282-2284, 2296, 2297, 2307, 2310-2312,
2314, 2315, 2317, 2319, 2321, 2330-2336

1 - 1B5174 Plug (Cylinder Block)
1 - 2B858 Plug (Cylinder Block)
2 - 4J4382 Plug (Exhaust Elbow)
2 - 1N4734 Clamp (Turbo Oil Supply Line)
1 - 7C9944 Bracket As. (Front Lifting Eye Clamp)
2 - 9M1974 Washer (Front Lifting Eye Clamp)
4 - S1617 Bolt (Front Lifting Eye Clamp)
1 - 7C9941 Manifold (RH)
1 - 7C9942 Manifold (LH)
1 - 7C9943 Manifold (Crossover)
1 - 9L2295 Bolt (LH Crossover Manifold)9 - 2N2766 Locknut
8 - 5P2755 Bolt
2 - 7N4903 Gasket (Manifold)
2 - 7N4904 Gasket (Manifold)
1 - 5P3931 Thread Compound
1 - 2P2333 Sealer

See the attached Procedure.

Product Caterpillar Dealer Suggested Customer Suggested
smu Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(D/N) (Cost) (C/L) (Sell)
0-4000 100% 5 0 0 0 0
4001-8000 33 1/3% 1.3 0 1.2 50% 2.5
NOTE: This is a 5-hour job.

Handle the parts in accordance with your Warranty Bulletin on
warranty parts handling.
Attach. (1-Rework Procedure)

1. If the engine is equipped with one or two tube assemblies that
connect the air plenum in the cylinder block to the turbocharger exhaust
elbow, remove them. Plug the openings in the cylinder block with 2B858
and 1B5174 Plugs. Use two 4J4382 Plugs to close the openings in the
exhaust elbow. See Illustration 1.
2. Remove the two 8N2755 Clamps shown in Illustration 1 and replace
with two 1N4734 Clamps to retain the turbocharger oil supply tube.
****** IMAGE: SEBE3769.01001.001
CAPTION: ILLUSTRATION 1
3. Remove the 8N2407 and 8N2408 Clips from the front end of the
aftercooler housing. Install the 7C9944 Bracket Assembly and the clips
using four S1617 Bolts, two 9M1974 Washers and existing 9N869 Washers on
the aftercooler as shown in Illustration 2. These changes will cause
the front lifting eye group to be stored in a more vertical position.
****** IMAGE: SEBE3769.01001.002
CAPTION: ILLUSTRATION 2
-2 of 2-
4. Remove the front sections from the right-hand and left-hand exhaust
manifolds.
5. Apply a thin coat of 2P2333 Sealer to the outside diameter at each
end of the 7C9943 Manifold. Bolt the 7C9943 Manifold to the 7C9942
Manifold using the 9L2295 Bolt and one 2N2766 Locknut. Remove any
excess sealer after assembly.
6. Install the left-hand manifold section with the crossover section
assembled, using a 7N4904 Gasket between the manifold section and the
block and a 7N4903 Gasket between the manifold sections. Apply 5P3931
Thread Compound to the 5P2755 Bolts before fastening the manifold
sections.
7. Install the right-hand manifold to the crossover section and mount
the manifold to the block using a 7N4904 Gasket between the manifold and
block and a 7N4903 Gasket between the manifold sections. Apply 5P3931
Thread Compound to the 5P2755 Bolts before fastening the manifold
sections. Remove any excess sealer from the joint between the right-
hand manifold and the crossover section after assembly. Refer to
Illustration 3 for final assembly of manifolds.
****** IMAGE: SEBE3769.01001.003
CAPTION: ILLUSTRATION 3