SERVICE BULLETIN

NOTICE: Service Bulletins are proprietary to Solar Turbines Switzerland SAGL, Via Campagna 15, CH-6595
Riazzino, Switzerland. The Type of Change and Recommended Compliance specified reflects Solar Turbines’s
best judgment regarding the Service Bulletin. All questions should be directed to your Solar Turbines Field
Service Representative. Solar, Saturn, Centaur, Taurus, Mercury, Mars, Titan, SoLoNOx, and Turbotronic are
trademarks of Solar Turbines Incorporated. Cat and Caterpillar are trademarks of Caterpillar Inc. Specifications
subject to change without notice.

NUMBER: 7.1/113B
ISSUED: 12.02.2016
REVISION: 07.02.2024
PRODUCT: CENTAUR 40, CENTAUR 50, MERCURY 50, MARS 100,
SATURN 10, SATURN 20, TAURUS 60, TAURUS 65,
TAURUS 70, TITAN 130
MODEL(S): Generator Set
Specifics: Turbomach Legacy packages and PGM products
INSPECTION AND MAINTENANCE OF GULL-WING
SUBJECT:
DOORS
Type of Change: Product Safety
Recommended Immediate
Compliance:
Type of Mechanical
Modification:

- Revision notice -
General document review and added detailed hinges inspection criteria
Added PNs information for additional checks
Disclaimer for Customers

PURPOSE:
To inform about inspection and maintenance of the lifting system for package enclosure
gull-wing doors in order to mitigate the risks related to excessive deterioration of these
lifting systems and possible safety hazard due to mechanical failure.

GENERAL INFORMATION:
Hinges are used to secure the gull-wing doors to the enclosure so that they can rotate open
and closed. Gas springs are used to help lift and maintain the package gull-wing doors in
the open position.

Template SB Page 1 of 17
rev. ed – 01.01.2022

Caterpillar: Confidential Green

 The gas spring structure includes pressure tube, piston rod, oil seal, oil, along with several
other components.

Aging and excessive deterioration of these components may present a safety hazard and
result in the partial or total loss of the gas pressure in the pressure tube.

It is strongly recommended to replace the gas spring when it loses force (indicated by the
door not fully opening or if is difficult to open), or when the rod is deteriorated, starts to
show signs of rust or corrosion (see Figures 1 and 2 below).

For the safety of personnel and to maintain the package enclosure doors in good condition,
it is necessary to check all gas springs and all hinge assemblies, including bolts, and threads
for all gull wing doors, for good and safe operation.

Gull-wing door assembly inspection as described in the Action Required section

of this document, must be conducted at every site visit.

In addition to the mandatory inspection required during maintenance activities,

it is necessary to replace all gas spring assemblies (pistons, self-locking nuts,
safety pin) at every engine exchange regardless of the state of wear and tear, at
latest every five (5) years, whichever is shorter.

Figures 1 & 2 - Rod pistons deteriorate

Template SB Page 2 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 Figure 3 – Gas Spring Assembly and bracket in a very bad state and tear

Template SB Page 3 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 Refer to the table below to obtain the Part Number (PN) installed on different package model and enclosure configuration:

(From CPD 670)

(OFF Skid) (*)

C40/C50/T60
C40/C50/T60
Turbomach PN Solar PN Description Enclosure

(ON Skid)
S10/S20

T70 HED

PGM130
PGM60

PGM70

PGM70
M100
T130

M50
T65

T70
42420003 - Gas Spring 900 [N] 85dBA X X X X X X X X

42420012 - Gas Spring 1000 [N] 85dBA X X

42420008 - Gas Spring 500 [N] Auxiliary Panel 85dBA X X X

42420004 1522260-1 Gas Spring 1200 [N] 80dBA X X X X X X X X X

(replaced by Solar PN)

42420013 1522260-2 Gas Spring 1300 [N] 80dBA X X X X

(replaced by Solar PN)

42420015 - Gas Spring 1500 [N] 75 dBA X

42510310 1599655 Self-locking Nut, 10mm thickness All X X X X X X X X X X X X

42200115 Rod-end with 30mm thread Only if required X X X X X X X X

- 2903428-1 Safety pin for ball socket d16 All X X X X X X X X X X X X

- 2900273-1 Warning Sticker All X X X X X X X X X X X X

48102566 - Hinge kit (serves for 3 doors) STD.GM.011 TBM Legacy X X X X X X X X X

rev. ab

- 1519720-100 Hinge PGM70 & PGM130 X X

- 1801422-100 Hinge PGM60 & PGM70 X X

48102953 - Door Bracket TBM Legacy X X X X X X X X X

- 1522275-100 Door Bracket PGM Product X X X X

- 1522274-1 Enclosure Bracket PGM Product X X

- 1975524-1 Enclosure Bracket PGM Product X X

Table 1 – Part Number list

(*) TBM Legacy C40-C50-T60 OFF-Skid package has different doors dimension and consequently different types of gas springs. Refer to page 5 for the
configuration.

Template SB Page 4 of 17
rev. ed – 01.01.2022

Caterpillar: Confidential Green

 Gull-Wing Doors configuration for TBM Legacy C40-C50-T60 OFF-Skid

Figures below show a package fully configured with gull-wing doors. The number of gull-
wing doors will vary and must be verified based on the dedicated project.

Figure 4 – TBM Legacy C40-C50T60 OFF-Skid side view

Figure 5 – TBM Legacy C40-C50-T60 OFF-Skid side view

Yellow Doors
Dimensions: 840x2040mm and 986x2040
Enclosure 85 dBA: Gas Spring PN 42420003 (900 N)
Enclosure 80 dBA: Gas Spring PN 1522260-1 (1200 N)

Green Doors
Dimensions: 940x2300mm
Enclosure 85 dBA: Gas Spring PN 42420012 (1000 N)
Enclosure 80 dBA: Gas Spring PN 1522260-2 (1300 N)

Template SB Page 5 of 17
rev. ed – 01.01.2022

Caterpillar: Confidential Green

 Gull-Wing Doors frontal panel configuration for TBM Legacy C40-C50-T60 ON-
Skid

Some older C40/C50/T60 ON-Skid units were equipped with a frontal panel to access to
the control and electrical panels.

This feature impacts a limited number of units, i.e., approx. 15 packages currently in
operation.

In these cases, the gull-wing frontal panel is equipped with two (2) Gas Spring PN
1522260-1 (1200 N).

Figure 6 – Gull-wing frontal panel

Template SB Page 6 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 Gull-Wing Doors auxiliary panel configuration for TBM Legacy C40-C50-T60
ON-Skid, M50 and T65

Some older C40/C50/T60 ON-Skid, M50 and T65 units were equipped with a gull-wing
panel to access to the auxiliary components.

In these cases, the gull-wing auxiliary panel is equipped with two (2) Gas Spring PN
42420008 (500 N).

Figure 7 & 8 – Gull-wing on Auxiliary panel

Template SB Page 7 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 Gas spring assembly composition:
- gas spring
- rod-ends
- safety pins

Figure 7 - Example of Gas Spring Assembly

ACTION REQUIRED:

This task must be carefully planned in collaboration with experienced Solar field personnel
including input from Regional Field Engineer, Fleet Manager, Field Service Supervisor and/or
District Service Manager, as needed. Any concerns should be brought to the attention of the
Customer Service Technical Services group via the RFE by opening a TechConnect Case.
Completion of a comprehensive site survey, Workplace Hazard Assessment (WHA), and
Task Risk Assessment (TRA) plays a critical role in identifying any hazards or obstacles that
could impact field activities.

Key areas are listed below and must be carefully examined during the mandatory
completion of the WHA and TRA prior to commencing work:

• Access to and from the package - Access for tooling and temporary lifting fixtures,

•
provision of walkways or temporary platforms
Overhead environment - Identify lifting points or potential obstacles to lifting, i.e.

•
height restrictions
Local or regional considerations that would prohibit or impede the use of temporary

•
lifting fixtures

•
Requirements for hot work
LOTO (lock-out/tag-out) and isolation practices in compliance with Solar
requirements, and local or regional requirements and practices

DO NOT GRAB THE GAS SPRING TO PULL YOURSELF UP WHEN YOU

ENTER THE PACKAGE ENCLOSURE

Perform a Workplace Hazard Assessment and a Task Risk

Assessment before starting any work.

Perform a normal system shutdown, allow equipment to coast

down to a complete stop, and allow the post-lubrication cycle to
automatically stop.
Template SB Page 8 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 Follow appropriate hazardous energy sources lock-out and tag-out
procedures for the entire turbomachinery package, ancillaries, and
associated equipment.

Isolate the package from all sources of fuel and start gas including
any gas exhaust system and vent system.

Allow surfaces in the proximity of the work area to cool adequately

to eliminate any burn hazard to personnel.

Equipment damage issues. Use Warnings where personnel may be

at risk.

Any time a gull wing door is identified as potential source of

failure, it must be clearly marked: “DO NOT OPEN”.

Inform customer accordingly.

1. Lifting system Inspection

1.1 Gas spring condition

Inspect rod condition for wear and damage, and ensure the door opens completely.
If not, replace both (left and right) gas spring assemblies.

Figure 9 – Green check shows a gull-wing door that opens completely; red X shows a gull-wing
door that does not completely open

Template SB Page 9 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 1.2 Rod-ends

For every single gas spring, check rod-ends fixing and inspect for wear and damage
presence at both sides. Replace the complete gas spring assembly if necessary.

Figures 10 & 11 – Rod-end location and identification

1.3 Safety pins

Ensure the safety pin is present. Check for the correct installation and integrity of the
component. Safety pin PN 2903428-1.

Figures 12 & 13 - Safety pin identification

Template SB Page 10 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 1.4 Gas spring fixing bracket

Inspect fixing bracket on both ends for wear and correct installation. Fixing bracket
solutions may vary on different products.
a) TBM Legacy Packages:

Figure 14 – Turbomach Legacy doors fixing bracket (PN 48102953)

Figure 15 - Turbomach Legacy fixing bracket on enclosure.

b) PGM130 & PGM70

Figure 16 – PGM130 part numbers

Template SB Page 11 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 c) PGM60 & PGM70 (from CPD 670)

Figure 17 – PGM60 and PGM70 part numbers

1.5 Rod-end fixing

Ensure M10 self-locking nuts (PN 42510310) are present and tight. Self-locking part
of the nut must be completely tightened. Do not install washer.

Figures 18 & 19 – Rod-end self-locking nut, 10mm thickness

In some older packages, the fixing brackets are thicker, and the ball rod-end thread
is shorter. Only in those cases, order the rod-end with 30mm thread, PN 42200115.

Template SB Page 12 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 Below is an example of a thicker fixing bracket where the rod-end with 20mm threads
are installed. In this case, a rod-end of 30mm thread is required.

Figure 20 - Example of thicker bracket

DO NOT re-use self-locking nuts.

1.6 Danger / Warning Stickers

Ensure the Danger / Warning sticker is applied and well visible on each individual
gas spring. Replace if not readable.

Figure 21 – Danger / Warning Sticker layout, PN 2900273-1

Figure 22 – Danger / Warning Sticker applied

Template SB Page 13 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 Figure 23 – Danger / Warning Sticker applied

2. Door Hinges Inspection

• Replace the hinge if it shows cracks or damages.

2.1 Inspections of the gull wing door hinges and threads

• If threads are not in good condition, a new hole/thread must be created by

drilling a hole/thread next to the existing damaged one.

Figure 24 – Example of damaged hinge and threads

• Screw dimension must be M6x20mm. Hinges must be assembled by means of

five (5) screws to fix it on the door and five (5) screws to fix it on the enclosure

•
frame.
Flat washer must be used in the assembly.

Template SB Page 14 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 Powered screwdriver

To install/remove the screw, do not use powered screwdrivers!

Powered screwdrivers will damage the threads, compromising the necessary
mechanical strength.

Figure 25 – Powered screwdriver

• Screws must be tightened and untightened using only a manual Allen wrench
(Inbus key).

Recommended Torque
Thread Class 8.8 Class 10.9
M6 10.3 Nm 14.4 Nm

2.2 New thread execution

If new thread must be created, a minimum 130mm drill bit long, 5mm diameter for
a M6 thread, shall be used.

Figures 26, 27 and 28 – Phases of new thread execution

Template SB Page 15 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 Figure 29 – Drilling hole on door

2.3 Rubber Hinges

On packages built prior to 1997, rubber hinges may be present. Aging rubber may
lose its elasticity and fail. Therefore, it is necessary to exchange the rubber hinges
with the aluminium hinges. If threads are not in good condition, a new hole/thread
must be created by drilling a new hole/thread next to the existing/damaged one.

Figure 30 – Example of rubber hinges to replace with aluminium hinges

Template SB Page 16 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 3. Replacement rules

Any time a gull wing door is identified as potential source of

failure, it must be clearly marked: “DO NOT OPEN”.

Inform customer accordingly.

DO NOT replace gas spring with higher or lower force than the
required as specified in Table 1.

- Undertake immediate action to remedy the situation when there is a potential source of
failure.
- When there is a problem with the gas springs assembly or a potential source of failure
on a rod-end, it is mandatory to replace the complete gas spring assembly and self-
locking nuts at both sides (left and right) of the gull wing door.
- New gas springs are supplied with rod ends and safety pins. It is mandatory to replace
the complete assembly. Self-locking nuts shall be ordered separately. Old parts must
not be re-used.
- When a safety pin is missing but all the other hardware is in good condition, you may
order and install only the safety pin.
- Fixing bracket must be inspected for wear and corrosion. Replace as necessary.
Welding activity is required to replace the fixing bracket on the enclosure.
- Replace the Danger / Warning sticker if it is no longer visible or readable.
- Damaged hinges must be immediately replaced.
- Damaged hinge assemblies must be immediately replaced.

4. Periodic Maintenance replacement

Replace all gas spring assembly (pistons, self-locking nuts, safety pin) at every engine
exchange regardless of the state of wear and tear, and at latest every five (5) years.

If you are experiencing issues with gull-wing doors, contact your local Solar
Turbines District Office for further information.
Template SB Page 17 of 17
rev. ed – 03.01.2022

Caterpillar: Confidential Green

 Disclaimer

TO ALL CUSTOMERS WITH PACKAGES EQUIPPED WITH GULL-WINGS DOORS

Dear Valued Customer,

As part of our commitment to optimize the performance and safety of our equipment, we
refer to Service Bulletin SB7.1/113B, released and provided to you on February 05,
2024.

Please review and diligently adhere to the guidelines for the maintenance and operation of
the enclosure gullwing-type doors, as detailed in SB7.1/113B. These guidelines are crucial
for ensuring the safety of personnel, as well as the longevity and efficiency of the equipment.

We are dedicated to fulfilling our contractual obligations, please consult with your Solar
Turbines contact to confirm any costs associated with carrying out the tasks outlined in
SB7.1/113B.

Should you have any questions or require further clarification, please do not hesitate to
reach out to our customer support team.

Thank you for your understanding and collaboration.

Best regards,

Fleet Manager / Field Service Supervisor / Contract Manager