PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE TURBO WATER LINES GROUP ON CERTAIN 3512B AND 3516B MARINE PROPULSION ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE TURBO WATER LINES GROUP ON CERTAIN 3512B AND 3516B MARINE PROPULSION ENGINES

Usage:

REBE1609-00

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16Feb2007

U-59

O-53

TM-3

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE TURBO WATER LINES GROUP ON CERTAIN 3512B AND 3516B MARINE PROPULSION ENGINES
1380		PI10577

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10577" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI10577" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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PROBLEM

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The turbo water lines group must to be inspected and if necessary reworked on certain 3500B marine propulsion engines. Failure to complete this rework can lead to a coolant leak and possibly a fire or engine shutdown. A fire or loss of engine power may impact the ability to control a vessel, which may result in personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3512B	MKH00100-00103, 200-207

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*****Group 2*****
3516B	PAG00100-00109

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
4	1B2714	BOLT
2	2544100	COUPLING
2	2544101	COUPLING AS
1	2632569	TUBE AS
1	2632570	TUBE AS
3	2672217	HOSE AS
4	2760792	CLAMP
1	2760793	BRACKET
2	2760794	PLATE
1	2870416	TUBE AS
1	2870417	TUBE AS
1	2T2171	ELBOW-O-RING
4	3E9865	LOCKNUT
2	5K9090	SEAL-O RING
8	5P0537	WASHER-HARD
2	6V1903	SEAL-O-RING
4	6V8398	SEAL-O-RING
2	7L4773	SEAL-O-RING
1	7S3916	CLIP
1	7S3919	CLIP
1	8C8989	ELBOW
2	8M2770	CLIP
*****Group 2*****
1	0911442	SPACER
1	0T0065	BOLT
1	1240174	CLIP-LOOP
4	1B2714	BOLT
2	2544100	COUPLING
2	2544101	COUPLING AS
1	2632569	TUBE AS
1	2632570	TUBE AS
3	2672217	HOSE AS
4	2760792	CLAMP
1	2760793	BRACKET
2	2760794	PLATE
1	2870416	TUBE AS
1	2870417	TUBE AS
1	2T2171	ELBOW-O-RING
4	3E9865	LOCKNUT
2	5K9090	SEAL-O RING
8	5P0537	WASHER-HARD
1	6K5535	CLIP
1	6K5536	BRACKET
2	6V1903	SEAL-O-RING
4	6V8398	SEAL-O-RING
2	7L4773	SEAL-O-RING
1	8C8989	ELBOW
1	8M2770	CLIP

ACTION REQUIRED

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Refer to attached rework procedure

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 3.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 3.0-hour job for Group 2

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE TURBO WATER LINES GROUP

MODELS INVOLVED - CERTAIN 3512B AND 3516B MARINE PROPULSION ENGINES

Dear Caterpillar Product Owner:

The turbo water lines group must be inspected and if necessary reworked on certain 3500B marine propulsion engines. Failure to complete this rework can lead to a coolant leak and possibly a fire or engine shutdown. A fire or loss of engine power may impact the ability to control a vessel, which may result in personal injury or death.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 16Feb2007 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 16Feb2007 Service Letter

Rework Procedure

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Group Number 1

INSPECTION ? 3512B TURBO WATER LINES GROUP

Perform the three inspections listed below and rework as required. The following inspections and rework procedures are for a 3512B engine, see the section below titled INSPECTION ? 3516B TURBO WATER LINES GROUP for a 3516B engine.

1. Inspect the cooling lines that are installed at the wastegate. If the cooling lines at the wastegate are rigid tubes and not hoses as shown in image 1.2.1, they must be replaced. The required rework is described in the section titled REWORK ? 3512B WASTEGATE COOLING LINES.

Image1.2.1

2. Inspect the left and right turbo cooling return lines. If the return lines do not include the coupling assembly as shown in image 1.3.1, they must be replaced. The required rework is described in the section titled REWORK ? 3512B LEFT AND RIGHT TURBO COOLING RETURN LINES.

Image1.3.1

3. Inspect the clamps that are securing the turbo cooling lines at the rear of the engine. If the clamps are made of steel and not rubber as shown in image 1.4.1, they must be replaced. The required rework is described in the section titled REWORK ? 3512B TURBO COOLING LINES SUPPORT CLAMPS

Image1.4.1

REWORK ? 3512B WASTEGATE COOLING LINES

If the inspection has determined that this rework is needed, replace the tubes at the wastegate with hoses as described below. See images following the instructions for additional details.

1. Remove the tube and fitting that is attached at the right side of the wastegate. Replace the fitting with 2T-2171 elbow with 6V-8398 seal. Replace the tube assembly with a 287-0417 tube assembly with 6V-8398 seal and 267-2217 hose assembly. Use one 8M-2770 clip to secure the 287-0417 tube assembly to the side of the right manifold shield.

2. Remove the coolant return tube from the tee at the the left side of the wastegate. Replace the tube assembly with a 287-0416 tube assembly with 6V-8398 seal and 267-2217 hose assembly. Use an 8M-2770 clip to secure the 287-0416 tube assembly to the outboard side of the 238-7840 bracket assembly.

Image1.6.1

3. Remove the vent tube from the tee at the left side of the wastegate. Orient the tee that attaches at the vent line so it is pointing straight down instead of back towards the wastegate (see image 1.7.1). Install 8C-8989 elbow with 6V-8398 seal on the vent tee and install a 267-2217 hose assembly between the elbow and the tee at the wastegate. Orient the elbow and hose assembly as shown in image 1.7.1.

Image1.7.1

REWORK ? 3512B LEFT AND RIGHT TURBO COOLING RETURN LINES

If the inspection has determined that this rework is needed, replace left and right turbo cooling return lines as described below. See photos beneath the instructions for additional details.

1. Remove the coolant return line between the left turbo coupling and the 150-3057 tee. The clip that supported the line will not be reused but the hardware will be reused to install a two piece clamp.

2. Remove the coupling at the left turbo and replace with a 254-4100 coupling with 5K-9090 seal and 6V-1903 seal.

3. Install a 254-4101 coupling assembly at the 150-3057 tee. Use the hardware from step 1 with 7S-3916 and 7S-3919 two piece clip to secure the coupling to the 238-7840 bracket assembly.

4. Install 263-2569 tube assembly with with 7L-4773 seal between the coupling at the turbo and the coupling assembly at the tee.

Image1.9.1

5. Remove the coolant return line between the right turbo coupling and the 148-8429 tee.

6. Remove the coupling at the right turbo and replace with a 254-4100 coupling with 5K-9090 seal and 6V-1903 seal.

7. Install a 254-4101 coupling assembly at the 148-8429 tee.

8. Install 263-2570 tube assembly with with 7L-4773 seal between the coupling at the turbo and the coupling assembly at the tee.

Image1.10.1

REWORK ? 3512B TURBO COOLING LINES SUPPORT CLAMPS

If the inspection has determined that this rework is needed, replace the turbo cooling line support clamps at the rear of the engine as described below. See image 1.12.1 for additional details.

1. Remove the metal clips and bracket that are securing the left and right turbo cooling lines. The hardware used to install the bracket will be used to install the new bracket.

2. Install 276-0793 bracket with hardware from step 1.

3. Install (2) 276-0792 rubber clamps on each line using using (1) 276-0794 plate, (2)1B-2714 Bolts, (4) 5P-0537 washers and (2) 3E-9865 locknuts as shown in image 1.12.1.

Image1.12.1

Group Number 2

INSPECTION ? 3516B TURBO WATER LINES GROUP

Perform the three inspections listed below and rework as required. The following inspections and rework procedures are for a 3516B engine, see the section above titled INSPECTION ? 3512B TURBO WATER LINES GROUP for a 3512B engine.

1. Inspect the cooling lines that are installed at the wastegate. If the cooling lines at the wastegate are rigid tubes and not hoses as shown in image 2.2.1, they must be replaced. The required rework is described in the section titled REWORK ? 3516B WASTEGATE COOLING LINES.

Image2.2.1

2. Inspect the left and right turbo cooling return lines. If the return lines do not include the coupling assembly as shown in image 2.3.1, they must be replaced. The required rework is described in the section titled REWORK ? 3516B LEFT AND RIGHT TURBO COOLING RETURN LINES.

Image2.3.1

3. Inspect the clamps that are securing the turbo cooling lines at the rear of the engine. If the clamps are made of steel and not rubber as shown in image 2.4.1, they must be replaced. The required rework is described in the section titled REWORK ? 3516B TURBO COOLING LINES SUPPORT CLAMPS

Image2.4.1

REWORK ? 3516B WASTEGATE COOLING LINES

If the inspection has determined that this rework is needed, replace the tubes at the wastegate with hoses as described below. See images following the instructions for additional details.

1. Remove the tube and fitting that is attached at the right side of the wastegate. Replace the fitting with 2T-2171 elbow with 6V-8398 seal. Replace the tube assembly with a 287-0417 tube assembly with 6V-8398 seal and 267-2217 hose assembly. Use a 124-0174 clip with 191-1442 spacer, 0T-0065 bolt and 5M-2894 washer to secure the 287-0417 tube assembly at the back of the air manifold (see image 2.6.1 and 2.7.1).

2. Remove the coolant return tube from the tee at the the left side of the wastegate. Replace the tube assembly with a 287-0416 tube assembly with 6V-8398 seal and 267-2217 hose assembly. Use one 8M-2770 clip to secure the 287-0416 tube assembly to the outboard side of the 238-7840 bracket assembly (see image 2.6.1 and image 2.7.1).

Image2.6.1

3. Remove the vent tube from the 148-8444 tee at the left side of the wastegate. Orient the 148-8444 tee that attaches at the vent line so it is pointing straight down instead of back towards the wastegate (see image 2.7.1). Install 8C-8989 elbow with 6V-8398 seal on the vent tee and install a 267-2217 hose assembly between the elbow and the tee at the wastegate. Orient the elbow and hose assembly as shown in image 2.7.1.

Image2.7.1

REWORK ? 3516B LEFT AND RIGHT TURBO COOLING RETURN LINES

If the inspection has determined that this rework is needed, replace left and right turbo cooling return lines as described below. See images beneath the instructions for additional details.

1. Remove the coolant return line between the left turbo coupling and the 150-3057 tee. The clip that supported the line will not be reused but the hardware will be reused to install a two piece clamp.

2. Remove the coupling at the left turbo and replace with a 254-4100 coupling with 5K-9090 seal and 6V-1903 seal.

3. Install a 254-4101 coupling assembly at the 150-3057 tee. Use the hardware from step 1 with 6K6535 and 6K-6536 two piece clip to secure the coupling to the 238-7840 bracket assembly.

4. Install 263-2569 tube assembly with with 7L-4773 seal between the coupling at the turbo and the coupling assembly at the tee.

Image2.9.1

Image2.10.1

REWORK ? 3516B TURBO COOLING LINES SUPPORT CLAMPS

If the inspection has determined that this rework is needed, replace the turbo cooling line support clamps at the rear of the engine as described below. See image 2.12.1 for additional details.