PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST SYSTEM ON CERTAIN 3512C HD AND 3516C HD MARINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST SYSTEM ON CERTAIN 3512C HD AND 3516C HD MARINE ENGINES

Usage:

TEBE4016-07

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15Jun2016

(Revised 15May2018)

U-314

A-306

D-351

O-273

TM-5

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST SYSTEM ON CERTAIN 3512C HD AND 3516C HD MARINE ENGINES
1061 1059 1067		PS53237

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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 can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53237" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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 15Jun2016 (Revised 15May2017) Service Letter. Changes have been made to the Termination Date, and Affected Product.

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TERMINATION DATE

30Jun2019

PROBLEM

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The existing exhaust system can leak on certain 3512C HD and 3516C HD Marine Engines. If the existing system leaks an entire replacement of the exhaust log design to the bolted flange design for improved robustness and avoiding repeat leaks.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3512C HD	T3R00200-00226, 235-290, 293-305, 309-311, 315, 327-328, 335, 337

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*****Group 2*****
3512C HD	T3W00202-00229, 231, 237-244, 249-250, 255-261, 265, 273-274 T3Y00200 TKP00200-00207, 220-223

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*****Group 3*****
3512C HD	T3P00200-00227, 230-231, 234-235, 237-238, 244-272, 275-288, 291-319, 321-324 T3S00200-00221

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*****Group 4*****
3516C HD	TKT00202-00203, 220-221, 224-243 TKX00202-00205 TKY00200-00207, 232-245, 257-260, 268-269, 281, 283, 285, 290, 296, 302, 355-357

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*****Group 5*****
3516C HD	TKR00200-00248, 250, 253-255 TKS00200-00266

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
19	0S0509	BOLT
4	1W4658	CLAMP-V-BAND
17	2H3755	BOLT
80	2N2766	LOCKNUT
12	4P7680	SPACER-HIGH TEMP
12	4S5898	SEAL-O-RING
1	5B4399	SEAL-O RING
74	5M2894	WASHER-HARD
4	6J2680	SEAL-O-RING
12	6V9769	SEAL-O-RING
80	7L6443	BOLT-HEX HEAD
3	8T1919	SEAL-O-RING
4	9L2295	BOLT-HEX HEAD
48	9L7373	BOLT-HIGH TEMP
17	9M1974	WASHER-HARD
1	1003145	MANIFOLD-EXHAUST
4	1003146	MANIFOLD-EXHAUST
1	1003147	MANIFOLD-EXHAUST
4	1003148	MANIFOLD-EXHAUST
4	1077954	SPACER-HIGH TEMP
2	1097411	SEAL-O-RING
160	1108314	WASHER
2	1228856	GASKET AS
4	1674407	SEAL-O-RING
4	1808424	SEAL-O-RING
10	2224701	BELLOWS AS
2	2254340	CLAMP
2	2287089	SEAL-O-RING-ORFS
22	2295333	SEAL (see Service Claim Allowances)
2	2301072	GASKET
2	2616847	ADAPTER
4	2840753	WASHER-SST
3	2949072	SEAL-O-RING-ORFS
2	3014515	SHIELD
4	3025889	CLAMP-V-BAND
1	3451924	GASKET
2	3487062	SEAL-PIP
10	3808583	BRACKET AS
1	3808616	BRACKET AS
1	3808617	BRACKET AS
2	3840516	BELLOWS AS
1	4161269	BRACKET AS
12	4289129	GASKET
22	4289130	GASKET (see Service Claim Allowances)
5	4289132	GASKET
2	4461290	CLAMP
1	4895365	MANIFOLD-EXHAUST
1	4895366	MANIFOLD-EXHAUST
1	4899246	BELLOWS AS
1	4899247	BELLOWS AS
1	4899248	ADAPTER
2	4900654	BELLOWS AS
1	4960831	SHIELD AS
2	4960832	SHIELD AS
1	4960833	SHIELD AS
1	4960835	SHIELD AS
1	4978018	SHIELD AS
1	4978019	SHIELD AS
1	4978020	SHIELD AS
1	4978021	BRACKET
1	4978022	BRACKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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.
*****Group 2*****
19	0S0509	BOLT
4	1W4658	CLAMP-V-BAND
17	2H3755	BOLT
80	2N2766	LOCKNUT
12	4P7680	SPACER-HIGH TEMP
12	4S5898	SEAL-O-RING
1	5B4399	SEAL-O RING
74	5M2894	WASHER-HARD
4	6J2680	SEAL-O-RING
12	6V9769	SEAL-O-RING
80	7L6443	BOLT-HEX HEAD
3	8T1919	SEAL-O-RING
4	9L2295	BOLT-HEX HEAD
48	9L7373	BOLT-HIGH TEMP
17	9M1974	WASHER-HARD
1	1003145	MANIFOLD-EXHAUST
4	1003146	MANIFOLD-EXHAUST
1	1003147	MANIFOLD-EXHAUST
4	1003148	MANIFOLD-EXHAUST
4	1077954	SPACER-HIGH TEMP
2	1097411	SEAL-O-RING
160	1108314	WASHER
2	1228856	GASKET AS
4	1674407	SEAL-O-RING
4	1808424	SEAL-O-RING
10	2224701	BELLOWS AS
2	2287089	SEAL-O-RING-ORFS
20	2295333	SEAL (see Service Claim Allowances)
2	2301072	GASKET
2	2616847	ADAPTER
4	2840753	WASHER-SST
3	2949072	SEAL-O-RING-ORFS
2	3014515	SHIELD
2	3440079	BELLOWS AS
1	3451924	GASKET
2	3487062	SEAL-PIP
10	3808583	BRACKET AS
1	3808616	BRACKET AS
1	3808617	BRACKET AS
1	4161269	BRACKET AS
12	4289129	GASKET
20	4289130	GASKET (see Service Claim Allowances)
5	4289132	GASKET
4	4346544	CLAMP
4	4674241	CLAMP
1	4895361	MANIFOLD-EXHAUST
1	4895362	MANIFOLD-EXHAUST
2	4899245	BELLOWS AS
1	4899248	ADAPTER
2	4900654	BELLOWS AS
2	4924705	GASKET-EXHAUST
1	4960831	SHIELD AS
2	4960832	SHIELD AS
1	4960833	SHIELD AS
1	4960835	SHIELD AS
1	4978018	SHIELD AS
1	4978019	SHIELD AS
1	4978020	SHIELD AS
1	4978021	BRACKET
1	4978022	BRACKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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.
*****Group 3*****
19	0S0509	BOLT
4	1W4658	CLAMP-V-BAND
17	2H3755	BOLT
80	2N2766	LOCKNUT
12	4P7680	SPACER-HIGH TEMP
12	4S5898	SEAL-O-RING
1	5B4399	SEAL-O RING
74	5M2894	WASHER-HARD
4	6J2680	SEAL-O-RING
12	6V9769	SEAL-O-RING
80	7L6443	BOLT-HEX HEAD
3	8T1919	SEAL-O-RING
48	9L7373	BOLT-HIGH TEMP
17	9M1974	WASHER-HARD
1	1003145	MANIFOLD-EXHAUST
4	1003146	MANIFOLD-EXHAUST
1	1003147	MANIFOLD-EXHAUST
4	1003148	MANIFOLD-EXHAUST
2	1097411	SEAL-O-RING
160	1108314	WASHER
2	1228856	GASKET AS
4	1674407	SEAL-O-RING
4	1808424	SEAL-O-RING
10	2224701	BELLOWS AS
2	2254340	CLAMP
2	2287089	SEAL-O-RING-ORFS
22	2295333	SEAL (see Service Claim Allowances)
2	2301072	GASKET
2	2616847	ADAPTER
6	2840753	WASHER-SST
3	2949072	SEAL-O-RING-ORFS
2	3014515	SHIELD
4	3025889	CLAMP-V-BAND
1	3451924	GASKET
2	3487062	SEAL-PIP
10	3808583	BRACKET AS
1	3808616	BRACKET AS
1	3808617	BRACKET AS
2	3840516	BELLOWS AS
1	4161269	BRACKET AS
12	4289129	GASKET
22	4289130	GASKET (see Service Claim Allowances)
2	4289132	GASKET
2	4461290	CLAMP
1	4895365	MANIFOLD-EXHAUST
1	4895366	MANIFOLD-EXHAUST
1	4899246	BELLOWS AS
1	4899247	BELLOWS AS
2	4905569	CAP
1	4960831	SHIELD AS
2	4960832	SHIELD AS
1	4960833	SHIELD AS
1	4960835	SHIELD AS
1	4978018	SHIELD AS
1	4978019	SHIELD AS
1	4978020	SHIELD AS
1	4978021	BRACKET
1	4978022	BRACKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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.
*****Group 4*****
25	0S0509	BOLT
32	0S1617	BOLT
7	0S1618	BOLT
4	1W4658	CLAMP-V-BAND
112	2N2766	LOCKNUT
16	4P7680	SPACER-HIGH TEMP
16	4S5898	SEAL-O-RING
6	5B4399	SEAL-O RING
4	5H8848	SEAL-O RING
89	5M2894	WASHER-HARD
8	6V2751	BOLT-HEX HEAD
2	6V3968	SEAL-O-RING
8	6V5839	WASHER-HARD
16	6V9769	SEAL-O-RING
112	7L6443	BOLT-HEX HEAD
3	8T1919	SEAL-O-RING
4	9L2295	BOLT-HEX HEAD
64	9L7373	BOLT-HIGH TEMP
32	9M1974	WASHER-HARD
1	1003145	MANIFOLD-EXHAUST
6	1003146	MANIFOLD-EXHAUST
1	1003147	MANIFOLD-EXHAUST
6	1003148	MANIFOLD-EXHAUST
4	1077954	SPACER-HIGH TEMP
2	1097411	SEAL-O-RING
224	1108314	WASHER
2	1121564	GASKET
2	1228856	GASKET AS
4	1274230	GASKET
7	1674407	SEAL-O-RING
4	1808424	SEAL-O-RING
14	2224701	BELLOWS AS
2	2287089	SEAL-O-RING-ORFS
28	2295333	SEAL (see Service Claim Allowances)
2	2301072	GASKET
2	2616847	ADAPTER
1	2798992	SEAL-O-RING
9	2840753	WASHER-SST
3	2949072	SEAL-O-RING-ORFS
2	3014516	SHIELD
2	3440079	BELLOWS AS
1	3451924	GASKET
4	3487061	SEAL-PIP
8	3808583	BRACKET AS
1	3808606	BRACKET
16	4289129	GASKET
28	4289130	GASKET (see Service Claim Allowances)
5	4289132	GASKET
4	4346544	CLAMP
4	4674241	CLAMP
1	4895361	MANIFOLD-EXHAUST
1	4895362	MANIFOLD-EXHAUST
2	4899245	BELLOWS AS
1	4899248	ADAPTER
2	4900654	BELLOWS AS
2	4924705	GASKET-EXHAUST
1	4960827	SHIELD AS
1	4960828	SHIELD AS
1	4960829	BRACKET
1	4960830	BRACKET
1	4960831	SHIELD AS
2	4960832	SHIELD AS
1	4960833	SHIELD AS
3	4960834	SHIELD AS
1	4960835	SHIELD AS
1	5004880	SHIELD AS
1	5004881	SHIELD AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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.
*****Group 5*****
25	0S0509	BOLT
32	0S1617	BOLT
7	0S1618	BOLT
4	1W4658	CLAMP-V-BAND
112	2N2766	LOCKNUT
16	4P7680	SPACER-HIGH TEMP
16	4S5898	SEAL-O-RING
6	5B4399	SEAL-O RING
4	5H8848	SEAL-O RING
89	5M2894	WASHER-HARD
8	6V2751	BOLT-HEX HEAD
2	6V3968	SEAL-O-RING
8	6V5839	WASHER-HARD
16	6V9769	SEAL-O-RING
112	7L6443	BOLT-HEX HEAD
3	8T1919	SEAL-O-RING
64	9L7373	BOLT-HIGH TEMP
32	9M1974	WASHER-HARD
1	1003145	MANIFOLD-EXHAUST
6	1003146	MANIFOLD-EXHAUST
1	1003147	MANIFOLD-EXHAUST
6	1003148	MANIFOLD-EXHAUST
2	1097411	SEAL-O-RING
224	1108314	WASHER
2	1121564	GASKET
2	1228856	GASKET AS
4	1274230	GASKET
7	1674407	SEAL-O-RING
4	1808424	SEAL-O-RING
14	2224701	BELLOWS AS
2	2287089	SEAL-O-RING-ORFS
28	2295333	SEAL (see Service Claim Allowances)
2	2301072	GASKET
2	2616847	ADAPTER
1	2798992	SEAL-O-RING
9	2840753	WASHER-SST
3	2949072	SEAL-O-RING-ORFS
2	3014516	SHIELD
2	3440079	BELLOWS AS
1	3451924	GASKET
4	3487061	SEAL-PIP
8	3808583	BRACKET AS
1	3808606	BRACKET
16	4289129	GASKET
28	4289130	GASKET (see Service Claim Allowances)
5	4289132	GASKET
4	4346544	CLAMP
4	4674241	CLAMP
1	4895361	MANIFOLD-EXHAUST
1	4895362	MANIFOLD-EXHAUST
2	4899245	BELLOWS AS
2	4905569	CAP
2	4924705	GASKET-EXHAUST
1	4960827	SHIELD AS
1	4960828	SHIELD AS
1	4960829	BRACKET
1	4960830	BRACKET
1	4960831	SHIELD AS
2	4960832	SHIELD AS
1	4960833	SHIELD AS
3	4960834	SHIELD AS
1	4960835	SHIELD AS
1	5004880	SHIELD AS
1	5004881	SHIELD AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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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This procedure will require the removal of the hard shields, entire exhaust system, some air, water and wastegate lines, water manifold, and air inlet manifold.

Refer to Disassembly and Assembly, UENR0114:

"Exhaust Manifold - Remove and Install", Removal Procedure, Steps 1 through 7

"Aftercooler - Remove and Install" Removal Procedure, Tube removal Steps 1 through 4

"Exhaust Bypass Valve - Remove and Install", Removal Procedure, Exhaust Bypass Valve removal Steps 1 through 4

"Crankcase Breather - Remove and Install", Removal Procedure, Crankcase breather removal Steps 1 and 2

"Air Inlet Manifold - Remove and Install", Removal Procedure, Skip part A and follow Steps 1 through 4

Refer to the attached Rework Procedure for the various seals and gaskets for reassembly as well as the following Disassembly and Assembly manuals.

Disassembly and Assembly, UENR0114

"Air Inlet Manifold - Remove and Install", Installation Procedure, Steps 1 through 4

"Aftercooler - Remove and Install", Installation Procedure, Steps 14 through 17

"Exhaust Bypass Valve - Remove and Install", Installation Procedure, Steps 3 through 6

"Crankcase Breather - Remove and Install", Installation Procedure, Steps 1 through 4

Disassembly and Assembly, SENR6564

"Exhaust Manifold - Remove and Install", Installation Procedure, Steps 1 through 6

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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%
*****Group 1*****
0-16000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 60.0-hour job for Group 1
Reasonable travel time and mileage is allowed. For other engines that are serviced on the same vessel, reference the other engine serial number(s) in the claim story. Exhaust gasket p/n 428-9130 or 229-5333 may be used for the repair. May only claim a total (combined for both part numbers) of 22 pcs for this repair.

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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%
*****Group 2*****
0-16000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 60.0-hour job for Group 2
Reasonable travel time and mileage is allowed. For other engines that are serviced on the same vessel, reference the other engine serial number(s) in the claim story. Exhaust gasket p/n 428-9130 or 229-5333 may be used for the repair. May only claim a total (combined for both part numbers) of 20 pcs for this repair.

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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%
*****Group 3*****
0-16000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 60.0-hour job for Group 3
Reasonable travel time and mileage is allowed. For other engines that are serviced on the same vessel, reference the other engine serial number(s) in the claim story. Exhaust gasket p/n 428-9130 or 229-5333 may be used for the repair. May only claim a total (combined for both part numbers) of 22 pcs for this repair.

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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%
*****Group 4*****
0-16000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 60.0-hour job for Group 4
Reasonable travel time and mileage is allowed. For other engines that are serviced on the same vessel, reference the other engine serial number(s) in the claim story. Exhaust gasket p/n 428-9130 or 229-5333 may be used for the repair. May only claim a total (combined for both part numbers) of 28 pcs for this repair.

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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%
*****Group 5*****
0-16000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 60.0-hour job for Group 5
Reasonable travel time and mileage is allowed. For other engines that are serviced on the same vessel, reference the other engine serial number(s) in the claim story. Exhaust gasket p/n 428-9130 or 229-5333 may be used for the repair. May only claim a total (combined for both part numbers) of 28 pcs for this repair.

PARTS DISPOSITION

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

Rework Procedure

The water manifold should be removed for easier assembly and torqueing of the exhaust log and bellows joints. After removing the turbo box heat shields inspect bellows and clamps for any signs of shield wear. Also inspect the inside of the shields for wear. If any wear is present use a rubber mallet to adjust the inner liner of shield to prevent rubbing during reassembly. If wear marks are present then photo document the wear and contact your local customer service rep. to notify them of the wear area.

After the old exhaust system is removed from the engine please install the new exhaust system utilizing the following process. Please use a click wrench on all clamps or a tool that turns less than 60 rpm. Please be aware that the numbering is the same for small and large frame 3512 and 3516 engines. Please reference the correct chart for specific part numbers.

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Remove the old heat shield rails from the cylinder heads. Install new rails (32 - 36) starting from the rear of the engine. Secure water neck at head to 25 nm. Secure rails to 25 nm.

Install wastegate adapter casting (11) with gasket (5) to exhaust elbow with bolts (12) washers (13A) and spacers (13B). Leave loose. Connect the turbine inlet bellows (8) to the turbo with clamp (9) for both sides of the engine. Ensure bellows arrow is facing towards turbo. Install hand tight. Do not apply any lubricant to the inside of the clamp or the bolt threads.

Connect the rear most log bellows (23) with gasket (25) to the Y manifold (1 & 2). Ensure bellows arrows are facing towards turbo. Please ensure the gasket is in the manifold groove. Apply C5-A Anti-Seize to bolts (27) washers (26) and nuts (28) and secure to 55nm.

Connect the wastegate bellows (6) to the Y manifold (1 & 2) with clamp (7) and gasket (5) only hand tight. Ensure bellows arrow is facing towards exhaust elbow. Do not apply any lubricant to the inside of the clamp or the bolt threads. Also place clamp (7) onto wastegate adapter loosely and insert gasket (5) into wastegate adapter groove in preparation for y-manifold install. Install the Y manifold (1 & 2) to the engine. Apply C5-A Anti-Seize to Y manifold bolts (14) washer (15) spacer (16) and leave loose.

Connect the turbine inlet bellows (8) to the Y manifold (1 & 2) with clamp (9) and gasket (10) only hand tight. Connect the wastegate bellows (6) to the wastegate adapter with previously placed clamp (7) and gasket (5) only hand tight. Properly orient turbo to ensure all bellows convolutions are not constrained. If the turbo is misaligned and was previously pinned, remove pin and ensure proper alignment. Secure Y manifold bolts to 55nm. Secure wastegate adapter bolts to 55nm. Please ensure all bellows retainer rings are completely seated inside the clamp retainer. Secure all turbine inlet clamps to 17nm and all wastegate clamps to 8nm. Do not tap clamps and do not retorque. Perform turbo pinning procedure if necessary via SIS Media REHS9660.

Ensure all bellows arrows are pointing towards the turbos. Torque head joints prior to bellows flange joints. Install manifold (21 or 22) to head with gasket (24). Apply C5-A Anti-Seize to bolts (14) washers (15) spacer (16) and secure to 55nm. Install bellows (23) ensuring flow arrow on bellows is facing toward the turbos and install gasket (25) between manifold segments. Apply C5-A Anti-Seize to bolts (27) washers (26) nuts (28)and secure to 55nm. Repeat for rest of exhaust log assembly. The last manifold piece will be (19 or 20).

Reinstall the air inlet manifold and water manifold with gaskets and O-rings. Secure water manifold to regulator housing with gasket to 47nm. Reinstall water manifold support brackets and secure to 25nm. Install new insert shield (46) over the log manifolds. Then install the log shield (37 or 38) by sliding the rear end under the turbo box and rotating the front down into place over the log inner shield. Align bolt holes with water manifold. Install the aftercooler brackets (41) and secure all bolts (42 & 44) washers (43 & 45). Please ensure the heat shield rail is behind the water manifold tube and not under the flange.

Inspect the inside of the shields for wear. If any wear is present use a rubber mallet to adjust the inner liner of shield to prevent rubbing during reassembly. If wear marks are present then photo document the wear and contact your local customer service rep. to notify them of the wear area. The right hand turbine inlet bellows shield has a known interference that must be removed with a rubber mallet. Please reference the before and after images below.