Turbocharger Exhaust Leaks on 3512B and 3516B Marine Engines Caterpillar


Turbocharger Exhaust Leaks on 3512B and 3516B Marine Engines

Usage:

REBE1722-00

26Jul2007


U-359
A-296
D-298
O-322
TM-17

 
After Failure Only
  
  

TURBOCHARGER EXHAUST LEAKS ON 3512B AND 3516B MARINE ENGINES

1052
PS51340
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 "PS51340" 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.

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.


TERMINATION DATE

31Jul2009

PROBLEM

Exhaust is leaking between the turbine housing and turbo cartridge.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
3512B 2EZ00235-00375

8EM00361-00373, 376-385, 387-401, 403-404, 409-410, 415, 417-430, 433-444, 447-451, 455-463, 465, 467-468, 470-486, 491-492, 494-502, 505-508, 515, 517-526, 532-537, 546-561

S2J00101-00103, 105-114, 117-118, 121-154, 159, 164-177, 179-181, 183-187, 189-197, 201-205, 207, 210-217, 221-227, 229-230, 232-233, 235, 238-240, 242-245, 252-253, 256-277, 281-297, 305-310, 312-314, 320, 322-334, 336-337, 340, 342-346, 348, 350-353, 355-356, 358-359, 362-363, 365, 367-374, 376, 380-384, 386-387, 389, 392-400, 411, 413-414, 416-417, 425-426, 433-434, 436-437, 439-440, 446-447, 449, 453-458, 463-467, 471-474, 476-479, 482-485, 487-490

S2M00114-00115, 117-118, 120-121, 130-141, 155-158, 163-164
3516B  8KN00418-00420, 425-431, 433, 435, 442-447, 449-454, 457-466, 475-483, 486-492, 499-515, 520-521, 525-526, 529-531, 534-536, 539-552, 554-562, 567-573, 575-578, 581-587
*******Group  2*******
3512B 4TN00401, 403, 405-439, 445-450, 452-456, 459-469, 471, 473-478, 483-484, 487-493, 498-499, 501-504, 508, 512-515, 517-518, 521-526, 530, 532, 534, 536-545, 549-558, 562, 565-566, 568-569, 573-612, 614, 617-624, 626-631, 633-644, 646, 649-677, 681-690, 692, 694, 696-703, 705-710, 714, 716-717, 721-727, 730, 732-735, 740-746, 748-756, 761-763, 765-766, 769-770, 774-775, 778, 780-787, 795, 798-800, 805-812, 814, 816-819, 821-823, 825-840, 845-849, 851-855, 858-861, 864-867

8EM00374-00375, 386, 402, 405-408, 416, 431-432, 445-446, 453-454, 464, 466, 469, 487-490, 493, 503-504, 509-514, 516, 527-531, 538-545

S2L00100-00128, 135-137, 140-209, 216-262, 265-492, 495-618, 620-623, 625-629, 631-635, 637-638, 641-642, 645-680
*******Group  3*******
3512B S2J00104, 115-116, 119-120, 155-158, 160-163, 178, 182, 188, 198-200, 206, 208-209, 218-220, 228, 231, 234, 236-237, 241, 246-251, 254-255, 278-280, 298-304, 311, 315-319, 321, 335, 338-339, 341, 347, 349, 354, 357, 360-361, 364, 366, 375, 377-379, 385, 388, 390-391, 401-410, 431-432, 441-442, 444-445, 448, 450-452, 459-462, 468-470, 475, 480-481, 486

S2M00106-00107, 110-111, 116, 119, 122, 124, 142-154, 159-162, 165-168, 170

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
8 2N2765 BOLT-FLANGE HEAD
8 2N2766 LOCKNUT
20 5M2894 WASHER-HARD
12 6V1943 BOLT-HIGH TEMP
4 6V3917 SEAL-O-RING
8 6V6753 BOLT-HIGH TEMP
2 1215736 GASKET-TURBO
16 1255375 BOLT
2 1548741 SEAL-O-RING
4 2071382 GASKET-EXHAUST
2 2071390 BELLOWS AS
2 2894078 HOUSING-TURBINE
2 2894079 GASKET
*******Group 2*******
8 2N2765 BOLT-FLANGE HEAD
8 2N2766 LOCKNUT
20 5M2894 WASHER-HARD
12 6V1943 BOLT-HIGH TEMP
4 6V3917 SEAL-O-RING
8 6V6753 BOLT-HIGH TEMP
2 1215736 GASKET-TURBO
16 1255375 BOLT
2 1548741 SEAL-O-RING
4 2071382 GASKET-EXHAUST
2 2071390 BELLOWS AS
2 2894079 GASKET
2 2947492 HOUSING-TURBINE
*******Group 3*******
8 2N2765 BOLT-FLANGE HEAD
8 2N2766 LOCKNUT
20 5M2894 WASHER-HARD
12 6V1943 BOLT-HIGH TEMP
4 6V3917 SEAL-O-RING
8 6V6753 BOLT-HIGH TEMP
2 1215736 GASKET-TURBO
16 1255375 BOLT
2 1548741 SEAL-O-RING
4 2071382 GASKET-EXHAUST
2 2071390 BELLOWS AS
2 2894079 GASKET
2 2944527 HOUSING-TURBINE

ACTION REQUIRED

Replace turbine housing with new turbine housing and spiral wound seal. Refer to attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-15000 hrs 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 15.0-hour job for Group 1

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-15000 hrs 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 15.0-hour job for Group 2

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-15000 hrs 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 15.0-hour job for Group 3



PARTS DISPOSITION

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


Rework Procedure


Group Number 1  
 
Replace the turbine housings with new housings incorporating a spiral wound seal, as well as bellows, seals and related hardware as shown on the attached images. Use the applicable Disassembly and Assembly Manual to remove and replace the turbine housing. Use new seals and hardware as shown in the attached images. Replace the compressor housing seal if the original is disturbed or damaged during this process. Be sure to lubricate the seals for the compressor outlet with glycerine or approved equal before installation.
Image1.1.1
Image1.1.2
Image1.1.3
 
 
Group Number 2  
 
Replace the turbine housings with new housings incorporating a spiral wound seal, as well as bellows, seals and related hardware as shown on the attached images. Use the applicable Disassembly and Assembly Manual to remove and replace the turbine housing. Use new seals and hardware as shown in the attached images. Replace the compressor housing seal if the original is disturbed or damaged during this process. Be sure to lubricate the seals for the compressor outlet with glycerine or approved equal before installation.
Image2.1.1
Image2.1.2
Image2.1.3
 
 
Group Number 3  
 
Replace the turbine housings with new housings incorporating a spiral wound seal, as well as bellows, seals and related hardware as shown on the attached images. Use the applicable Disassembly and Assembly Manual to remove and replace the turbine housing. Use new seals and hardware as shown in the attached images. Replace the compressor housing seal if the original is disturbed or damaged during this process. Be sure to lubricate the seals for the compressor outlet with glycerine or approved equal before installation.
Image3.1.1
Image3.1.2
Image3.1.3
 
 

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