SERVICE BULLETIN

NOTICE: The Type of Change and Recommended Compliance specified reflects Solars best judgment regarding the Service
Bulletin. All questions should be directed to your Solar 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:
ISSUED:
REVISED:
PRODUCT:
MODEL(S):
Specifics:

8.12/109H
April 2007
April 2015
Centaur 40, Centaur 50, Taurus 60
Compressor Set, Mechanical Drive, Hot-End-Drive Generator Set
Equipment with a 30- or 36-inch-Diameter Marman-Style
Exhaust-Collector Discharge Flange

SUBJECT:

INTRODUCTION OF BOLTED FLANGES AND DISCONTINUATION

OF MARMAN FLANGES FOR RIGHT-ANGLE-DISCHARGE
EXHAUST COLLECTORS AND BELLOWS
REVISION NOTICE
Added Centaur 40 bellows blanket kit and updated Table 4

Type of Change:

Product Improvement

Recommended
Compliance:

Information

Purpose:

To announce a repair/replacement procedure for worn exhaust collector outlet flanges and
bellows inlet flanges that improves durability and necessitates the use of bolted-flange
components.

To announce the discontinued availability of Marman flanged exhaust collectors, expansion

bellows and repair flanges for affected product lines.

GENERAL INFORMATION:
In 1998, Solar issued Service Bulletin 11.6/101 addressing exhaust bellows durability concerns.
The bulletin focused on wear of the Marman flanges interfacing between the bellows and exhaust
collector. In some cases, wear resulted in exhaust gas leakage and flange failure. The service
bulletin introduced a more uniform bellows flange, designed to reduce fretting problems. However,
wear issues still persist on some Centaur 40, Centaur 50, and Taurus 60 two-shaft engines.

SERVICE BULLETIN
NUMBER: 8.12/109H

Caterpillar Confidential: Green

Page 1 of 16

Centaur 40, Centaur 50 and Taurus 60 two-shaft engines have right-angle discharge exhaust
collectors. To improve reliability where Marman flange wear occurs, Solar introduced a
bolted-style flange (Figure ) on exhaust collectors and mating bellows for Centaur 50 and Taurus
60 units in 2007.

Figure 1 The New Bolted Flange Interface Mitigates Wear and Fretting (Centaur 50 shown)

Used on larger engine models for many years, the bolted joint with gasket has proven to be a more
durable interface design. Following release of the Centaur 50 / Taurus 60 design improvement, it
became evident that Centaur 40 two-shaft engines can also benefit from the bolted-flange design.
Therefore, the bolted-flange design has been adopted for Centaur 40 two-shaft engines.
Discontinued Availability of Marman-Flanged Components and Repair Parts
Effective immediately for Centaur 40s and beginning January 2012 for Centaur 50s and Taurus
60s, right-angle exhaust collectors, mating expansion bellows, and repair flanges will only
be available with bolted flanges. Marman-flanged components for these products are being
discontinued.
Existing equipment need not be upgraded until component condition necessitates repair or
replacement.

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SERVICE BULLETIN
NUMBER: 8.12/109H

Exhaust System Description

For the purposes of this document, the exhaust system for two-shaft engines will be discussed as
having three major sections:
1.

Exhaust Collector (connecting to the turbine engine)

2.

Exhaust Bellows (thermal expansion joint)

3.

Exhaust Duct (point of interface with the rest of the exhaust system further downstream)
NOTE
Inlet refers to the flow inlet side of each piece; Exit is the flow exit (outlet
or discharge) side of the piece. This terminology will be used throughout
this Service Bulletin.

Centaur 40 Improvements
Converting the Centaur 40 exhaust collector exit flange from Marman to bolted style requires
accommodating 3 different configurations.
The Marman flange configuration (Existing Design, Figure 2) and the new bolted-flange
configuration (New Design, Figure 2) are depicted below.

Figure 2 Centaur 40 Design Improvement

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NUMBER: 8.12/109H

Caterpillar Confidential: Green

Page 3 of 16

The new configuration has three exhaust bellows options to accommodate the exhaust duct inlets
which have:

Different flange sizes

Different bolt hole diameters

Different bolt hole patterns

Hardware part numbers and details can be found in the Hardware Replacement section of this
service bulletin.

1.

Exhaust Collector The new production exhaust collector design eliminates the Marman
flange (legacy flange, Figure 3) and introduces the bolted exit-flange (new production
flange, Figure 3).

Figure 3 Centaur 40 Marman Flange vs. the Improved Flange Design

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SERVICE BULLETIN
NUMBER: 8.12/109H

2.

Exhaust Bellows Three new bellows designs have been created. Each of the three
designs has the same inlet flange as the exhaust collector exit flange shown above.
However, there are three different exit flange options as shown in Figure 4. The exit
flanges possess a slip system that permits rotation of the flange for easier alignment
of bolt holes during installation.

Figure 4 Centaur 40 Bellows Exit Flange Options

3.

Exhaust Duct Inlet The bellows exit flange options (Figure 4, above) are intended
to provide a means of matching bolt patterns and flange diameters with the adjoining
exhaust duct inlet flange located immediately downstream of the bellows.

SERVICE BULLETIN
NUMBER: 8.12/109H

Caterpillar Confidential: Green

Page 5 of 16

Centaur 50 and Taurus 60 Improvements Introduced in 2007

The legacy configuration (pre-2007 design, Figure 5) and the improved configuration (current
design, Figure 5) are depicted below.

Figure 5 Centaur 50 and Taurus 60 Design Improvement

The new configuration has two options to accommodate bolt diameters of either 0.75 or 1.50 as
dictated by the exhaust duct inlet flange:

Initially, exhaust duct inlet flanges were designed for 1.50 diameter bolts.

In 1992, the bolt size was changed to 0.75. The current standard production is still the
0.75 bolt pattern.

Hardware part numbers and details can be found in the Hardware Replacement section of this
service bulletin.
1.

Page 6 of 16

Exhaust Collector - The new production exhaust collector design introduced in 2007
eliminated the Marman flange (legacy flange, Figure 6) and introduced the bolted
exit-flange (new production flange, Figure 6).

Caterpillar Confidential: Green

SERVICE BULLETIN
NUMBER: 8.12/109H

Figure 6 Centaur 50 and Taurus 60 Marman Flange vs. the

Improved Flange Design

2.

Exhaust Bellows Each of the two new-production exhaust bellows designs have the
same inlet flange as the new-production exhaust collector exit flange shown above. The
exhaust bellows designs have two exit flange options as shown below in Figure 7. The
exit flanges possess a slip system that permits rotation of the flange for easier alignment
of bolt holes during installation.

Figure 7 Centaur 50 and Taurus 60 Bellows Exit Flange Options

3.

Exhaust Duct Inlet The bellows exit flange options (Figure 7, above) are intended to
provide a means of matching bolt diameters with the adjoining exhaust duct inlet flange
located immediately downstream of the bellows.

SERVICE BULLETIN
NUMBER: 8.12/109H

Caterpillar Confidential: Green

Page 7 of 16

ACTION REQUIRED:

Risk mitigation practices must be in place before starting any work;

comply with all local and employer risk mitigation requirements.
Equipment and systems should complete normal shutdown cycles,
coast down to a complete stop, and complete post-lubrication cycles
before commencing work.
Hazardous energy isolation lock-out and tag-out (LOTO) is required.
Isolations and procedures for the turbomachinery package, ancillaries, and associated equipment/systems must be appropriate to the
work being completed.
Hot surfaces may be present, exposing personnel to burn injury hazards. Allow surfaces in the proximity of the work area to adequately
cool, removing the hazard. Combustible gases or vapors may be
present. Test for combustible gases and vapors; if present, stop
work until safe levels are achieved. Fuel and ignition sources must
be isolated and controlled via LOTO.

Please review the two approaches presented below if exhaust collector Marman flange wear issues
necessitate repair.
NOTE
1.

Please be aware that, for enclosed units, the additional bulk of the bolted flange may
require some modification to any interfering enclosure components in some cases.
Also, future engine removal might require temporary removal of additional panels and
supports.

2.

Marman replacement/repair flanges are no longer supported for Centaur 40, Centaur
50, and Taurus 60 two-shaft exhaust systems. The information contained herein is
presented with the intention of providing a durable exhaust collector exit flange repair
scheme, should repair become necessary. Conversion to a bolted-flange system is only
required if Marman flange replacement becomes necessary. However, when requesting
a replacement or spare exhaust collector or bellows of the Marman-flange-type through
Solars Service Parts depot, you will be presented with options for converting to a
bolted-flange arrangement.

Again, these are only repair procedures, not upgrade requirements. Units operating in the field
with no issues need not be modified. Please contact your local Solar Service Parts provider if
you are repairing a Marman flange connection at the exhaust collector and wish to purchase items
mentioned in this bulletin. All costs are to be covered by the owner/operator.
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SERVICE BULLETIN
NUMBER: 8.12/109H

Exhaust Collector Flange Repair - Welded Retrofit Approach

Retrofit kits have been developed to convert existing exhaust collector Marman flanges to the bolted
style. Kits include:

A separate bolt-style flange to be welded to the existing exhaust collector exit opening.

A new bellows with bolted flanges on both ends.

All necessary gaskets, bolts, washers, etc., to complete installation of the bellows to both
the exhaust collector side and the exhaust duct side.

It should be noted that all flange bolt patterns (Figures 3 and 6) are oriented to straddle the
centerlines as is standard practice in pipe work.
Please be prepared to handle cutting and welding issues on your own if you select this option.
Welding services will not be provided by Solar. Welding instructions are provided in the retrofit
kit installation instructions. The base material to be welded is composed of 0.090-inch-thick
type-409 corrosion-resistant (stainless) steel sheet per ASTM A176 or A240. The weld filler
material recommended can be either ER 308 or ER 409 stainless steel, both per AWS A5.9. The
filler material should be in wire form, 0.035 inches in diameter for metal-inert-gas arc welding
(MIG or GMAW) or 0.035 to 0.062 inches in diameter for tungsten-inert-gas arc welding (TIG
or GTAW). This material is not available from Solar. There are several good global sources in
existence for welding supplies.
To proceed with the welded upgrade approach, select the appropriate kit for your installation from
Tables or 2 below, depending on the engine.

SERVICE BULLETIN
NUMBER: 8.12/109H

Caterpillar Confidential: Green

Page 9 of 16

Table 1 Centaur 40 Weld-On Retrofit (Includes New Bolted-Collector

Flange, Bellows And Hardware)
ENGINE TO BE
UPGRADED

Engine

Centaur 40

ORDER ONE ALL INCLUSIVE KIT

Retrofit Kit Part
Number for Units
Installing to
Current 32 Bolt
Hole Pattern on the
Exhaust Duct Inlet

Retrofit Kit Part

Number for Units
Installing to
Legacy 28-Bolt
Hole Pattern on the
Exhaust Duct Inlet

Retrofit Kit Part

Number for Units
Installing to
Legacy 20 Bolt
Hole Pattern on the
Exhaust Duct Inlet

1090336-10X

1090336-20X
1090336-40X (for
Inconel bellows only)

1090336-30X

NOTE: The above information is current as of this writing, however, should this change, the most
current part number will be supplied when ordering.

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SERVICE BULLETIN
NUMBER: 8.12/109H

Table 2 Centaur 50 and Taurus 60 Weld-On Retrofit (Includes New

Bolted-Collector Flange, Bellows And Hardware)
ENGINE TO BE
UPGRADED

ORDER ONE ALL INCLUSIVE KIT

Engine

Retrofit Kit Part Number for

Units Using 0.75 Diameter
Bolts on the Exhaust Duct
Inlet Flange

Retrofit Kit Part Number for

Units Using 1.50 Diameter
Bolts on the Exhaust Duct
Inlet Flange

Centaur 50
(conventional
combustion)

1044517-50X

1044517-40X

Centaur 50S

1044517-30X

1044517-20X

Taurus 60
(conventional
combustion)

1044517-50X

1044517-40X

Taurus 60S

1044517-30X

1044517-20X

NOTE: The above information is current as of this writing, however, should this change, the most
current part number will be supplied when ordering.

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NUMBER: 8.12/109H

Caterpillar Confidential: Green

Page 11 of 16

1.

Centaur 40s use a 30-inch pipe diameter exhaust collector exit flange. Selection of the
proper kit is based upon the number of bolt holes used to connect the bellows exit
flange to the exhaust duct inlet flange.

2.

Centaur 50s and Taurus 60s both use 36-inch pipe diameter exhaust collector exit
flanges. Selection of the proper kit is based upon the bolt diameter used where the
bellows exit flange connects to the exhaust duct inlet flange.

3.

The retrofit kit includes a flange and ring assembly. The purpose of the ring is to slip
inside the exhaust collector and be welded in place. Feedback received from the field,
and subsequent dimensional inspection of inventory on hand indicates some of these
rings may be too large and have an interference fit. This was not the design intent.
ACTION: Prior to cutting the marman flange off the exhaust collector at site, measure
the OD of the flange (P/N 1102982-100) ring from kit P/N 1044517-XXX. if the ring OD
is larger than 36.15 + 0.03 inches, do not proceed with the flange retrofit. The supplier
has corrected the problem. Retrofit kits shipped after Octboer 13, 2014 are manufactured
per the drawing.

Figure 8

Complete Exhaust Collector Replacement Approach

Alternately, you may wish to purchase an entirely new exhaust collector to avoid welding. It should
be noted that all flange bolt patterns (Figures 4 and 7) are oriented to straddle the centerlines as is
standard practice in pipe work.
1.

Determine the engine model to be upgraded and consider the following:

a.

Centaur 40s use a 30-inch pipe-diameter exhaust-collector exit

flange.
From Table 3, select the exhaust collector and the appropriate
bellows kit based on the number of bolt holes in the existing
bellows-exit-flange-to-exhaust-duct-inlet-flange connection.

b.

Centaur 50s and Taurus 60s use 36-inch pipe diameter exhaust
collector exit flanges.
From Table 4, select the exhaust collector and
appropriate bellows kit based on the bolt diameter required on the existing
bellows-exit-flange-to-exhaust-duct-inlet-flange connection.

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SERVICE BULLETIN
NUMBER: 8.12/109H

Table 3 Centaur 40 Exhaust Collector Replacement - Select the Bellows That

Matches Number of Bolt Holes on the Exhaust Duct Inlet Flange
ENGINE TO BE
UPGRADED

Engine*

Centaur 40

Centaur 40S

ORDER ONE
EXHAUST
COLLECTOR

New Exhaust
Collector Part
Number

195095-50X
(with blankets)
or
111841-70X
(without
blankets)

195095-60X
(with blankets)
or
195112-30X
(without
blankets)

ORDER ONE BELLOWS KIT

(INCLUDES HARDWARE) **
Bellows Kit
PN for 32
Bolt Holes
and 0.75
Diameter
Bolts on the
Exit Flange

Bellows Kit
PN for 28
Bolt Holes
and 1.25
Diameter
Bolts on the
Exit Flange

Bellows Kit
PN for 20
Bolt Holes
and 0.75
Diameter
Bolts on the
Exit Flange

1090345-10X

-----

-----

-----

1090346-10X
1090346-20X
(for Inconel
bellows only)

-----

-----

-----

1091707-10X

1090345-10X

-----

-----

-----

1090346-10X
1090346-20X
(for Inconel
bellows only)

-----

-----

-----

1091707-10X

* For exhaust retrofit hardware for the Centaur 40L-5302 low speed turbine engine, contact your
local Solar District Service Office. This model typically utilizes a Taurus 60-7302 2-stage power
turbine but will require consultation to provide correct hardware for each specific site.
** For Centaur 40, order bellows blanket kit, P/N 1112954-10X. Kit includes bellows blanket, P/N
1112291-10X and flange blanket, P/N 1112292-10X.
NOTE: The above information is current as of this writing, however, should this change, the most
current part number will be supplied when ordering.

SERVICE BULLETIN
NUMBER: 8.12/109H

Caterpillar Confidential: Green

Page 13 of 16

Table 4 Centaur 50 and Taurus 60 Exhaust Collector Replacement

ORDER
ONE INLET
FLANGE
HARDWARE
KIT

ORDER
ONE EXIT
FLANGE
HARDWARE
KIT

Bellows
PN using
1.50 Bolt
Diameter
on Exit
Flange

Hardware
Kit
Bellows
Inlet
Flange

Hardware
Kit Bellows
Exit Flange

1100961-10X

-----

1073591-10X

1073591-10X

-----

1100961-30X

1073591-10X

AX-3608

1100961-10X

-----

1073591-10X

1073591-10X

-----

1100961-30X

1073591-10X

AX-3608

1097061-10X

-----

1073591-10X

1073591-10X

-----

1138267-100

1073591-10X

AX-3608

ENGINE
TO BE
UPGRADED

ORDER
ONE
EXHAUST
COLLECTOR

ORDER ONE BELLOWS

PLUS BLANKETS ***

Engine

New
Exhaust
Collector
Part Number

Bellows
PN using
0.75 Bolt
Diameter
on Exit
Flange

Centaur 50
-6102 and
-5702

136994-40X*
(with
blankets)
or
136500-100X*
(without
blankets)

Centaur 50
-6202 and
-5902

180146-40X*
(with
blankets)
or
180145-30X*
(without
blankets)

Centaur 50S
-6102 and
-5702

136994-50X**
(with
blankets)
or
136500-110X
**
(without
blankets)

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SERVICE BULLETIN
NUMBER: 8.12/109H

Table 4 Centaur 50 and Taurus 60 Exhaust Collector Replacement (Contd)

ORDER
ONE INLET
FLANGE
HARDWARE
KIT

ORDER
ONE EXIT
FLANGE
HARDWARE
KIT

Bellows
PN using
1.50 Bolt
Diameter
on Exit
Flange

Hardware
Kit
Bellows
Inlet
Flange

Hardware
Kit Bellows
Exit Flange

1097061-10X

-----

1073591-10X

1073591-10X

-----

1138267-100

1073591-10X

AX-3608

1100961-10X

-----

1073591-10X

1073591-10X

-----

1100961-30X

1073591-10X

AX-3608

1100961-10X

-----

1073591-10X

1073591-10X

-----

1100961-30X

1073591-10X

AX-3608

ENGINE
TO BE
UPGRADED

ORDER
ONE
EXHAUST
COLLECTOR

ORDER ONE BELLOWS

PLUS BLANKETS ***

Engine

New
Exhaust
Collector
Part Number

Bellows
PN using
0.75 Bolt
Diameter
on Exit
Flange

Centaur 50S
-6202 and
-5902

180146-60X**
(with
blankets)
or
180145-40X**
(without
blankets)
or
180146-40X*
(with
blankets)
or
180145-30X*
(without
blankets)

Taurus 60
-7302 and
-7802

180146-40X*
(with
blankets)
or
180145-30X*
(without
blankets)

Taurus 60M
-7002 and
-7302

180146-50X*
(with
blankets)
or
180145-30X*
(without
blankets)

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NUMBER: 8.12/109H

Caterpillar Confidential: Green

Page 15 of 16

Table 4 Centaur 50 and Taurus 60 Exhaust Collector Replacement (Contd)

ORDER
ONE INLET
FLANGE
HARDWARE
KIT

ORDER
ONE EXIT
FLANGE
HARDWARE
KIT

Bellows
PN using
1.50 Bolt
Diameter
on Exit
Flange

Hardware
Kit
Bellows
Inlet
Flange

Hardware
Kit Bellows
Exit Flange

1097061-10X

-----

1073591-10X

1073591-10X

-----

1138267-100

1073591-10X

AX-3608

ENGINE
TO BE
UPGRADED

ORDER
ONE
EXHAUST
COLLECTOR

ORDER ONE BELLOWS

PLUS BLANKETS ***

Engine

New
Exhaust
Collector
Part Number

Bellows
PN using
0.75 Bolt
Diameter
on Exit
Flange

Taurus 60S
-7302 and
-7802

180146-60X**
(with
blankets)
or
180145-40X**
(without
blankets)

*For engines with three-inch bleed ducts

**For engines with four-inch bleed ducts
***For Centaur 50 and Taurus 60, order bellows blanket, P/N 1091567-10X, and flange blanket,
P/N 1044587-10X.
NOTE: Ensure that the existing bleed duct size (3 or 4) on site matches that of the replacement
collector part being ordered. Contact your local Solar District Service Office for assistance. The
above information is current as of this writing, however, should this change, the most current part
number will be supplied when ordering.

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SERVICE BULLETIN
NUMBER: 8.12/109H