PRODUCT SUPPORT PROGRAM FOR REWORKING THE CLOSED CRANKCASE VENTILATION SYSTEM ON CERTAIN 3516C HD MARINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE CLOSED CRANKCASE VENTILATION SYSTEM ON CERTAIN 3516C HD MARINE ENGINES

Usage:

TEBE4659-03

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02Jun2016

(Revised 31Aug2016)

D241
D244
D246

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE CLOSED CRANKCASE VENTILATION SYSTEM ON CERTAIN 3516C HD MARINE ENGINES
1100 1000 7555 1317		PS45103

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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 "PS45103" 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 02Jun2016 (Revised 17Aug2016) Service Letter. Changes have been made to the Service Claim Allowances to add reasonable travel time and mileage. No parts or procedure changes.

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TERMINATION DATE

30Jun2018

PROBLEM

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Certain 3516C HD Marine Engines running at low loads for a long period of time can observe a pitting issue on the intake valves.

AFFECTED PRODUCT

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Model	Identification Number
3516C HD	TKT00200-00201, 204-219, 222-223

PARTS NEEDED

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Qty	Part Number	Description
4	0L2070	BOLT
4	0S1591	BOLT-HEX HEAD
2	2S4078	SEAL-O-RING
16	4S5898	SEAL-O-RING
8	5M2894	WASHER-HARD
6	5P0597	CLAMP-HOSE
3	5P4868	CLAMP-HOSE
16	6V9769	SEAL-O-RING
2	6V9830	CAP-ORFS
32	7N4782	SPRING-LFT GDE
4	7N6806	SEAL-RECTANGULAR
2	8T1919	SEAL-O-RING
2	9S6130	PLUG-LD STOR
4	9S8752	NUT-FULL
16	20R3545	HEAD GP-CYL BSC
2	1014197	COVER
2	1097411	SEAL-O-RING
2	1228856	GASKET AS
5	1674407	SEAL-O-RING
4	1808424	SEAL-O-RING
32	2147568	SEAL-O-RING-STOR
2	2176692	HOSE-TEE
2	2287089	SEAL-O-RING-ORFS
2	2287090	SEAL-O-RING-ORFS
2	2301072	GASKET
1	2385081	SEAL-O-RING-STOR
16	2454907	SEAL-FUEL SYSTEM
16	2454908	SEAL-FUEL SYSTEM
2	2720760	SEAL
1	2798992	SEAL-O-RING
3	2949072	SEAL-O-RING-ORFS
16	3550773	KIT-GASKET(SCH)
16	4289129	GASKET
1	SYSTEM	OPEN CRANKCASE VENTILATION SYSTEM
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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Rework the Tier 3 closed crankcase ventilation (CCV) system to have the system vented to atmosphere which will result in the system performing identical to a Tier 2 open crankcase ventilation (OCV) system. This program also includes the replacement of all cylinder heads and adjoining components gaskets and seals. The dealer contact for any piping rework questions is Wade Kullman with Louisiana Cat via wade.kullman@louisianacat.com or 985-631-0561.

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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%
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-8000 hrs, 25-36 mo	50.0%	100.0%	0.0%	0.0%	50.0%	0.0%
8001-12000 hrs, 37-48 mo	25.0%	100.0%	0.0%	0.0%	75.0%	0.0%
12001-15000 hrs, 49-60 mo	0.0%	100.0%	0.0%	0.0%	100.0%	0.0%

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NOTE: This is a 52.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Reasonable travel time and mileage is allowed. $7,670 allowance for materials and labor to convert the CCV system to an OCV system.

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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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The dealer will remove two existing valve covers with breather adapters and reinstall two new valve covers without the breather port. This will result in the set-up being similar to the existing 447-1459 Tier 2 OCV design.

The dealer will remove the existing Tier 3 CCV system components as referenced in Image 1.2.1 leaving the 6 breather adapters. The dealer will then install the Tier 2 OCV tee, hose, clamps and elbows to the breather adapters as referenced in Image 1.2.2.