244685 Volvo.Penta Spring disc

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 "PI3968" 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 "PI3968" 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.
This Revised Service Letter replaces the March 15, 1997 Service Letter. Changes have been made to the Parts Needed.
Completion Date
September 30, 1997Termination Date
March 31, 1998Problem
The coolant flow through the turbochargers on some 5230 Hydraulic Excavators is slow enough to allow the turbo heat to boil off the water and then burn the remaining coolant residue. This creates a dark colored coolant with a distinct burnt smell in the entire cooling system. The coolant temperature in the turbocharger will rise above the acceptable operating temperature of the 7N7628 Turbo Water Line Gasket. In these high operating temperatures this gasket will break down allowing leakage of coolant past this gasket.
Affected Product
Model & Identification Number
5230 (7LL1-51, 7LL53-66)
Parts Needed
16 - 3B1915 Bolt 1 - 5B2638 Bolt 4 - 1D4706 Bolt 5 - 7E6016 Gasket 1 - 7E9584 Elbow 4 - 6I4950 Regulator 2 - 6J7366 Cap 4 - 5K9090 Seal 1 - 6K8420 Locknut 2 - 0L1352 Bolt 1 - 7L7524 Bolt 8 - 8L2786 Seal 3 - 5M2894 Washer 1 - 7M8485 Seal 1 - 8M2888 Gasket 4 - 9M4584 Connector 1 - 2N0931 Gasket 1 - 7N4927 Gasket16 - 7N7628 Gasket 2 - 8N1269 Gasket 2 - 8N3640 Ring 8 - 2P7636 Connector12 - 4P0692 Clamp Assembly 2 - 5P1945 Reducer 1 - 5P7701 Seal 1 - 2R6276 Connector 3 - 0S1594 Bolt 2 - 9S8752 Nut 1 - 8T6765 Plug 4 - 6V4589 Seal 1 - 6V5050 Seal 2 - 6V5066 Seal-O-Ring 2 -6V8635 Connector 1 -6V8998 Union PARTS NEEDED CONT.
1 - 6V9027 Seal1 - 6V9172 Nut2 - 1W0764 Elbow1 - 4W3100 Gasket1 - 9Y4090 Housing4 - 0038581 Tee2 - 0618827 Tee8 - 1070744 Block1 - 1335964 Tube Assembly1 - 1335965 Tube Assembly1 - 1335966 Tube Assembly4 - 1335970 Hose Assembly1 - 1335971 Tube Assembly1 - 1335972 Tube Assembly1 - 1335971 Tube Assembly1 - 1335972 Tube Assembly1 - 1335975 Bracket1 - 1335977 Manifold1 - 1335978 Bracket1 - 1335982 Tube Assembly1 - 1335983 Tube Assembly2 - 1335984 Tube Assembly1 - 1335988 Elbow1 - 1378178 Housing Assembly1 - 1387100 Bracket Assembly2 - 1387531 Hose AssemblyAction Required
1. Drain engine coolant.2. Remove engine thermostat housing, the housing directly below the thermostat housing (8N9624 Housing), the 1W1561 Elbow, and the two 1170095 Outlet Elbows. Remove all plugs and covers, these will be reused in the replacement housings and elbows.3. Remove the turbo water supply and the turbo water return lines that connect the turbos to the radiator top tank. Remove all 7N7878 Covers and gasket material from the turbo bearing housings. Remove the left 2W2910 Elbow bolted to the radiator top tank. Remove the 1173521 Bracket Assembly.4. Install the new 9Y4090 Housing, 1378178 Housing Assembly and new thermostats, 7E9584 Elbow, and the 1W0764 Elbows. Be sure to replace all the plugs, plates, and gaskets.5. Install the new turbo water supply and return lines, as shown in Illustration 1. Replace all 7N7878 Covers using new 7N7628 Gaskets.
Illustration 16. Install the turbo return lines from the engine to the radiator top tank. Install the 1335988 Elbow to the radiator top tank, using a new gasket.7. Fill cooling system with coolant.Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
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