G3520C Generator Set GZN00001-UP(SEBP3868 - 22) - Systems & Components Page 1 of 5

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Product: GENERATOR SET

Model: G3520C GENERATOR SET GZN
Configuration: G3520C Generator Set GZN00001-UP

Technical Information Bulletin

Misalignment of the Exhaust Manifold and Bellows on G3500 C/E Generator Sets
{1052, 1059, 1061}
Media Number -TIBU4997-01 Publication Date -19/10/2007 Date Updated -19/10/2007
CONFIDENTIAL

i02683097

Misalignment of the Exhaust Manifold and Bellows on G3500

C/E Generator Sets{1052, 1059, 1061}
SMCS - 1052; 1059; 1061

Generator Set:
G3516C (S/N: GSB1-UP; TJB1-UP; TJD1-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

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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 view

Point (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 engine

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The 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

1. 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

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(4) Bolts

2. Loosen bolts (4) that connect elbow (2) to support bracket (3) .

Illustration 4 g01350359

Left side view

(5) Bolts

3. 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.

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.

5. Reinstall bolts (4) and support bracket (3) .

6. Tighten bolts (4) and (5) .

7. Install the new 227-9027 Bellows As .

8. Tighten the clamps.

a. Tighten the clamps to 25 ± 6 N·m (19 ± 5 lb ft).

b. Tap around the clamps with a soft faced hammer.

c. Tighten the clamps again to 25 ± 6 N·m (19 ± 5 lb ft).

9. Verify that the alignment of the bellows is correct.

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