PRODUCT SUPPORT PROGRAM FOR REWORKING THE DIESEL OXIDATION CATALYST ON CERTAIN 3512C LOCOMOTIVE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE DIESEL OXIDATION CATALYST ON CERTAIN 3512C LOCOMOTIVE ENGINES

Usage:

TEBE3373-04

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14Dec2015

(Revised 26Oct2016)

U-666

O-577

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING THE DIESEL OXIDATION CATALYST ON CERTAIN 3512C LOCOMOTIVE ENGINES
1059 1075		PS44939

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must 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 "PS44939" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 14Dec2015 (Revised 10Jun2016) Service Letter. A change has been made to the Service Claim Allowances.

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TERMINATION DATE

31Dec2017

PROBLEM

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The DOC (Diesel Oxidation Catalyst) needs to be reworked on certain 3512C Locomotive Engines. The existing internal insulation piece can break loose.

AFFECTED PRODUCT

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Model	Identification Number
3512C	NJT00102-00108, 110-122, 124-125, 127-135, 137-138, 140-141, 143-156, 158-159, 161-162, 164-178, 180-181, 184-187, 189-190, 192-193, 195-198, 200-231

PARTS NEEDED

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Qty	Part Number	Description
12	0S1590	BOLT
24	5M2894	WASHER-HARD
12	9S8752	NUT-FULL
1	2824168	GASKET
1	KIT	REWORK KIT (See Action Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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The rework kit and template will be provided by the factory. If necessary, email Dave Schluttenhofer at Schluttenhofer_David_H@cat.com to obtain the kit or template.

Refer to the attached Rework Procedure.

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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%
0-30000 hrs, 0-80 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 18.0-hour job
$50 allowed per/engine for any miscellaneous cost such as stripped bolts or split graphite washers.

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PARTS DISPOSITION

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

Rework Procedure

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Before completing the rework, review the all safety actions in the product's Operation and Maintenance Manual.
Ensure you have read and understand all of this document prior to beginning any work.

1 - Remove the DOC (Diesel Oxidation Catalyst) from the Locomotive. Refer to media SEBU8666, "Catalyst Module - Replace" for removal instructions.
Using a nail puller, remove the insulation retaining caps. Remove the exterior DOC insulation and set aside.
Slide protective sleeves over the insulation "nails" to prevent injury while re-working the DOC. Protective sleeves can be made from small rubber hose cut to length.
Reference Image 1.1.1

Image1.1.1

2 - Determine if the DOC (Diesel Oxidation Catalyst) can be reworked as is or needs to have new inside insulation pieces made.

Inspect the inside of the DOC through the 8" exhaust outlets to see the condition of the insulation and perforated plate. If the inside insulation and perforated plate is completely broken free, then the inside insulation pieces will need to be put back in their original location. If the insulation pieces are missing or damaged beyond repair then new insulation pieces will need to be made and installed into the DOC. The 1/2" insulation (shown in Green) is between the outer plate and the 1" insulation. The 1" insulation (shown in Red) is between the 1/2" insulation and the perforated plate.
Caution: If Fiberglass insulation pieces need to be made then the following PPE is required:
Dust mask, Kevlar arm sleeves, leather gloves and safety eye glasses with side shields.
A utility knife should be used to cut the insulation pieces.
Reference Image 1.2.1 for insulation positioning
Reference Image 1.2.2 for 1/2" insulation piece dimensions
Reference Image 1.2.3 for 1" insulation piece dimensions

Image1.2.1

Image1.2.2

Image1.2.3

3 - Using long straps and a crane, tilt the DOC on end so the outlet with the perforated plate end is facing up. With the DOC rotated on end, locate and center the drilling template and use C-Clamps to clamp the template in place so it does not shift.
With the DOC in this position ensure that all of the inside insulation pieces and the perforated plate are still in the correct position and in place.
Reference Image 1.3.1 and 1.3.2

Image1.3.1

Image1.3.2

4 - Position a mag base drill on the drilling template. While holding the inside perforated plate in position with a piece of 2" x 4" x 8' piece of lumber or other suitable size, drill the (4) 1.25" (31.75 mm) holes using a carbide tip cutter bit. Drill through the DOC end plate and insulation making sure the carbide tip cutter bit does NOT go through the perforated plate on the inside.

Note: A Hougen magnetic base drill works best for the drilling process and use a Hougen Copperhead Carbide Tip Annular Cutter bit. Hougen p/n 18240

Once the holes are drilled through clean out the drilled material.

Change out the carbide tip hole saw bit with a 3/8" drill bit. Ensure that the mag base drill stays in the same position so the 3/8" bit is drilling in the center of the 1.25" hole.
Note: The spacer can also be inserted in the 1.25" hole to use as a template to drill the 3/8" hole.
Drill a 3/8" hole through the inside perforated plate being careful not to drill too deep. From the outside end plate, the minimum drilling depth is 45 mm and the maximum drilling depth is 150 mm.

Note: This is a two person process with one person holding the inside perforated plate in place while the other person is drilling the holes. Additionally, the drilling through DOC should be done slowly as to not bend or drill through the perforated plate.
Reference Image 1.4.1 and 1.4.2

Image1.4.1

Image1.4.2

5 - Install the 1.25" spacer and slotted washer (Pacman washer) into each of the (4) drilled holes. The slotted washer will have to be angled in with needle nosed pliers and then moved in place in order to get it in the correct location. As an alternative to using needle nosed pliers, a thin wire tie can be tied around the slotted washer and lowered into the hole out of the way until it is re-positioned on top of the spacer.
Reference Images 1.5.1 and 1.5.2

Image1.5.1

Image1.5.2

6 - Once the spacer and slotted washer (Pacman washer) are installed in the DOC, install the 1.25" washer on top of the slotted washer. The 1.25" washer needs to be coated on both sides with Loctite 2620 sealant prior to installation.

From the outside of the DOC, install (2) each of the 3/8" bolt, small bolt washer, 2" washers and Graphite gasket through the holes in the slotted washers and spacers. On the inside of the DOC install an L Angle piece onto the lower 3/8" bolt threads and then install a flange nut on each bolt. Repeat this process for the upper (2) holes and upper L Angle in the DOC.
Tighten the 3/8' bolts and flange nuts to 47 +/- 9 nm
Note: Install Antisieze onto the threads of the 3/8" bolts prior to installing the flange nuts.
Reference Images 1.6.1 and 1.6.2
Perforated Plate repair complete

Image1.6.1

Image1.6.2

7 - The Inlet Cone needs to be inspected and removed if it is still in place. Using a crane and straps, tilt the DOC and use blocks and suitable supports so the inlet cone can be inspected and removed. Using a hand held grinder or tin snips, remove any pieces of the inlet cone that are still remaining in the DOC inlet. Additionally, remove any loose pieces of inlet cone that are in the DOC or engine exhaust outlet elbow.
Note: The cross bars will remain in tact and not need removed.
Reference Images 1.7.1 and 1.7.2

Image1.7.1

Image1.7.2

8 - Install the exterior DOC insulation blankets using new stainless steel wire. Reference Image 1.8.1
Prior to re-installing the DOC back to the locomotive, ensure that no loose pieces of the inlet cone are in the engine exhaust outlet elbow. Remove any loose pieces.
Install the DOC (Diesel Oxidation Catalyst) back to the Locomotive using new bolts, washers, nuts and gasket. Refer to media SEBU8666, "Catalyst Module - Replace" for removal/installation instructions.