PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER STUD ON CERTAIN C32 MARINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER STUD ON CERTAIN C32 MARINE ENGINES

Usage:

TEBE5764-00

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07Feb2017

U-76

A-50

D-58

O-59

TM-1

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER STUD ON CERTAIN C32 MARINE ENGINES
1052		PS45385

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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 "PS45385" 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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TERMINATION DATE

28Feb2019

PROBLEM

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The existing turbocharger stud can crack on certain C32 Marine Engines. If the existing turbocharger stud cracks, it can/will result in an exhaust leak.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C32	RPM00279-00667

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*****Group 2*****
C32	RPM00101-00278

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
4	2N2766	LOCKNUT
1	3K1787	GROMMET
1	4K1388	SEAL-O-RING-STOR
1	4L6454	BOLT-HEX HEAD
2	5M3062	BOLT-HEX HEAD
5	5P1075	WASHER-HARD
1	5P1947	ADAPTER-STR
2	5S7382	BOLT-HEX HEAD
1	6K6307	SEAL-O-RING
1	6V8801	NUT
1	7D1553	CLIP
3	8T4896	WASHER-HARD
2	8T4983	CLAMP-BAND
1	8T8915	BOLT
2	8T9101	BOLT
2	1984777	WASHER-HARD
1	1986068	SEAL-INTEGRAL
1	2556863	GASKET
1	2918145	SEAL-O-RING-STOR
1	3256994	CLIP-HALF SLOT
1	3256995	CLIP-HALF TAB
1	3571752	GASKET-TURBO (T)
1	3638595	SEAL-INTEGRAL
1	3854584	CLAMP AS-TURBINE
4	4857756	STUD-TAPERLOCK
1	4882435	HOUSING AS-TURB
1	4957448	BRACKET AS
1	4957452	BRACKET
1	4957453	HOSE-WATER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% 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*****
4	2N2766	LOCKNUT
1	3K1787	GROMMET
1	4K1388	SEAL-O-RING-STOR
1	4L6454	BOLT-HEX HEAD
2	5M3062	BOLT-HEX HEAD
5	5P1075	WASHER-HARD
1	5P1947	ADAPTER-STR
2	5S7382	BOLT-HEX HEAD
1	6K6307	SEAL-O-RING
1	6V8801	NUT
1	7D1553	CLIP
3	8T4896	WASHER-HARD
2	8T4983	CLAMP-BAND
1	8T8915	BOLT
2	8T9101	BOLT
2	1984777	WASHER-HARD
1	1986068	SEAL-INTEGRAL
1	2556863	GASKET
1	2918145	SEAL-O-RING-STOR
1	3256994	CLIP-HALF SLOT
1	3256995	CLIP-HALF TAB
1	3571752	GASKET-TURBO (T)
1	3638595	SEAL-INTEGRAL
1	3854584	CLAMP AS-TURBINE
1	4882435	HOUSING AS-TURB
1	4957448	BRACKET AS
1	4957452	BRACKET
1	4957453	HOSE-WATER
4	5165987	STUD-TAPERLOCK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% 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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Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".

Refer to the Service Manual if/as necessary.

1. Disconnect the turbocharger from the exhaust system riser.

2. Remove the right hand side turbocharger (as viewed standing at the flywheel housing and facing the heat exchanger). Refer to the C32 Marine Engine, Disassembly and Assembly, "Turbocharger ? Remove", for additional information.

3. Replace all the four existing turbocharger studs with four new taperlock studs.

- 485-7756 Taperlock Studs are required for GROUP 1 engines
- 516-5987 Taperlock Studs are required for GROUP 2 engines

4. Replace the existing turbine housing from the turbocharger with a new 488-2435 Turbine Housing Assembly. Ensure that a new 385-4584 Turbine Clamp Assembly is used. Refer to C32 Marine Engine, Specifications, for "Turbocharger", for turbine clamp torque value.

5. Remove the existing 418-9136 Water Hose installed between the right hand side exhaust riser and block, shown as Item 1, in Image1.

6. Remove the existing water line clip and fuel line bracket shown as Item 2, in Image1.

7. Remove the existing water line adapter shown as Item 3, in Image2.

8. Install the new 495-7448 Bracket Assembly to the flywheel housing using the two 8T-9101 Bolts and two 5P-1075 Washers at the upper two mounting holes and one 8T-8915 Bolt, 8T-4896 Washer, and 198-4777 Washer at the lower mount hole. Shown as Item 1, in Image1. Leave the bolts hand tight until final assembly.

9. Install the new 5P-1947 Water Line Adapter with a new 6K-6307 O-Ring Seal shown as Item 2, in Image1.

10. Install a new 495-7453 Water Hose using new 8T-4983 Hose Band Clamps shown as Item 3, in Image1.

11. Install a new 7D-1553 Water Hose Clip with a 5M-3062 Bolt and 5P-1075 Washer shown as Item 4, in Image 1.

12. Install the 495-7452 Fuel Line Support Bracket with a 5M-3062 Bolt and 5P-1075 Washer shown as Item 4, in Image1.

13. Install a 325-6994 Half Slot Clip, 325-6995 Half Tab Clip, and 3K-1787 Grommet around the existing fuel line using the 4L-6454 Bolt, 5P-1075 Washer, and 6V-8801 Nut shown as Item 4, in Image1.

14. Install the turbocharger. Refer to C32 Marine Engine, Disassembly and Assembly, "Turbocharger ? Install", for additional information. Ensure that the turbocharger water lines O-ring seals are replaced when they are installed into the compressor housing. Ensure that the turbocharger oil lines integral seals are replaced.

15. Connect the new 495-7448 Bracket Assembly to the 488-2435 Turbine Housing Assembly using two 5S-7382 Bolts, two 8T-4896 Washers, and two 198-4777 Washers. Tighten the bolts from Step 8 to ensure that there is not assembly stress on the bracket.

16. Connect the turbocharger to the exhaust system riser.

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Image1

Image2

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*****
0-5000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 7.0-hour job for Group 1
Reasonable travel time and mileage is allowed. On vessels with multiple affected engines this service letter should completed on all engines on the vessel on the same trip. Please reference the other engine serial numbers in the claim story. Note: $30 US Dollars miscellaneous cost is allowed for purchase of paint to match the engine.

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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*****
0-5000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 7.0-hour job for Group 2
Reasonable travel time and mileage is allowed. On vessels with multiple affected engines this service letter should completed on all engines on the vessel on the same trip. Please reference the other engine serial numbers in the claim story. Note: $30 US Dollars miscellaneous cost is allowed for purchase of paint to match the engine.