PRODUCT SUPPORT PROGRAM FOR REPLACING THE AFTERCOOLER BALANCE TUBE O-RING SEALS ON CERTAIN 789C AND 793C OFF HIGHWAY TRUCKS AND ON CERTAIN 3516B ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE AFTERCOOLER BALANCE TUBE O-RING SEALS ON CERTAIN 789C AND 793C OFF HIGHWAY TRUCKS AND ON CERTAIN 3516B ENGINES

Usage:

Caterpillar: Confidential Yellow

PRODUCT SUPPORT PROGRAM FOR REPLACING THE AFTERCOOLER BALANCE TUBE O-RING SEALS ON CERTAIN 789C AND 793C OFF HIGHWAY TRUCKS AND ON CERTAIN 3516B ENGINES SEBE7474

December 2, 2000

U-310
A-224
AU-184
S-144
H-111
O-254

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before or after failure	PRODUCT SUPPORT PROGRAM FOR REPLACING THE AFTERCOOLER BALANCE TUBE O-RING SEALS ON CERTAIN 789C AND 793C OFF HIGHWAY TRUCKS AND ON CERTAIN 3516B ENGINES
1058		PS40424

NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS40424" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: 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.

Termination Date

December 31, 2002

PROBLEM

The o-ring seals on the aftercooler air intake balance pipe may have been damaged on certain 3516B engines during the assembly process. Damaged o-rings seals may cause excessive black smoke and high exhaust temperatures resulting in poor engine performance. The o-rings seals will need to be replaced to ensure proper sealing.

AFFECTED PRODUCT

Model Identification Number

3516B 8NW234-246, 248-251, 256-259, 261

2JW278?286

6HN1026-1033, 1035-1036, 1038-1039, 1041-1042, 1044-1046, 1049-1054, 1056-1060, 1063-1070, 1072-1102, 1107-1117, 1119-1133, 1135-1204, 1206-1217, 1218-1220, 1222-1230, 1236, 1239-1240, 1242-1247, 1249, 1267, 1293-1296

7RN1493-1498, 1500-1501, 1503-1504, 1506-1507, 1510-1511, 1515, 1525-1526, 1528-1529, 1536, 1539-1540, 1551, 1555-1556, 1559-1561, 1563, 1566-1567, 1572-1574, 1577, 1581, 1599

789C 2BW306-312

793C ATY225

PARTS NEEDED

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QTY	Part Number	Part Name
2	6V0973	Seal
1	1073758	Seal-Aftercooler
2	1097411	Seal - O-Ring
3 Meters	5P6025	Cable w/Rope
3	5P8940	Seal - O-Ring

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-99999 months	100 %	2	0	0	0	0
NOTE: This is a 2-hour job.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach. (1-Rework Procedure)

Rework Procedure

Location of the 5P8940 O-Ring Seals

The aftercooler balance pipe is located between the front and rear aftercooler air intake housings. See Illustration #1.

Illustration #1 - Location of Aftercooler Balance Pipe

There are three 5P8940 O-ring seals on the aftercooler balance pipe that need to be replaced. Two O-rings are located on the front of the pipe and one is located on the rear of the pipe. See Illustration #2 for location of the O-ring seals.

Illustration #2 - Location of 5P8940 O-ring Seals

Disassembly Procedure

Remove the two bolts that connect the turbo compressor housing to the aftercooler air intake housing cover for each of the rear two turbos. See Illustration #3.

Illustration #3 - Bolt Location

Remove the heat shields that cover the turbo inlet if present.

Loosen the band clamp between the turbo compressor housing and the bearing housing. Loosen the band clamps between the turbo intake and the air inlet pipe. Perform this step on both rear turbos. See Illustration #4.

Illustration #4 ? Band-Clamp Location

To aid in the rotation of the turbo compressor housing, slide the rubber boot between on the turbo inlet and air intake pipe toward the rear of then engine. See Illustration #4.
Rotate the compressor housing on the left rear turbo counterclockwise away from the aftercooler air intake housing cover. See Illustration #5.

Illustration #5 ? Rotation Direction of Rear Turbos

Remove the eight bolts that connect the aftercooler air intake cover to aftercooler air intake housing. Carefully remove the aftercooler air intake cover.
Rotate the compressor housing on the right rear turbo clockwise away from the aftercooler air intake housing. See Illustration #5.

Remove the two bolts between the aftercooler balance pipe
and the rear aftercooler air intake housing.

Remove the six bolts that bolt the aftercooler air
intake housing to the aftercooler core.

10.Carefully pull the aftercooler air intake housing
upwards while separating the aftercooler balance pipe.

11.Remove the aftercooler balance pipe from the front
aftercooler air intake housing.

Cleaning Instructions

The O-ring grooves on the aftercooler balance tube and the O-ring bores on the aftercooler air intake housings need to be properly cleaned before re-assembly. Use a piece of Scotch Brite to thoroughly clean theses areas prior to assembly. Make sure to wipe the grooves and bores clean with a clean towel before re-assembly.

Assembly Instructions

Install three new 5P8940 O-rings to the aftercooler balance pipe.
Spray a generous amount of a water based O-ring assembly lubricant (ex. Glycerine) to the O-rings and the both front and rear bores.

NOTE: DO NOT USE 1U6396 O-Ring Compound.

Install the aftercooler balance pipe into the front aftercooler air intake housing. Slide the aftercooler balance pipe into front aftercooler air intake housing far enough for the rear aftercooler air intake housing to be installed with contacting the balance pipe.
Install a new 1073758 seal on the top of the rear aftercooler core.
Carefully install the rear aftercooler air intake housing to the rear aftercooler core making sure the seal is properly aligned to the air intake housing.
Torque the six bolts using the following three step torquing procedure.

Tighten by hand until contact with the housing.
Starting form the center working outward torque to 25 N?m.
Starting form the center working outward torque to 47 N?m.

Check the 1073758 seal for proper fit and alignment.
Slide the aftercooler balance pipe into the rear aftercooler air intake housing. Install the bolts and clamps and torque to 47 N?m.
Install two new 1097411 O-rings in the top of the rear aftercooler air intake housing. Install the rear aftercooler air intake housing cover. Torque the bolts to 47 N?m from side to side, front to rear of the housing.

10)Connect the turbo compressor housing to the aftercooler air
intake cover using two new 6V0973 O-rings. Torque to the
bolts to 47 N?m.

11)Reseat and locate the turbo band-clamps. Make sure the
housings are not in a bind or mis-aligned. Loosen the
compressor housing and relocate, if needed. Once the
housings are properly aligned, torque the band clamps to 14
N?m. Tap the clamp lightly all around and re-torque to 14
N?m.

12)Slide the rubber boots back onto the turbo air inlet and
tighten to 12 N?m.

13)Re-install the heat shields with 5P6025 cable if present.

14)Start the engine and check for leaks.