PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR LINES GROUP ON CERTAIN 3512C HD MARINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR LINES GROUP ON CERTAIN 3512C HD MARINE ENGINES

Usage:

REBE9118-01

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07Feb2013

(Revised 09Jul2013)

U-45

A-36

D-41

O-44

TM-2

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR LINES GROUP ON CERTAIN 3512C HD MARINE ENGINES
1071		PS43832

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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 "PS43832" 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 07Feb2013 Service Letter. Changes have been made to the Parts Needed and Rework Procedure.

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TERMINATION DATE

28Feb2015

PROBLEM

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The existing air lines group can crack or fail on certain 3512C HD Marine Engines. If the existing air lines group fails it can cause boost leaks.

AFFECTED PRODUCT

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Model	Identification Number
3512C HD	T3P00200-00203 T3R00202-00224 T3S00200-00203

PARTS NEEDED

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Qty	Part Number	Description
4	0S1571	BOLT
8	0S1588	BOLT
13	0S1594	BOLT
8	5M2894	WASHER-HARD
4	6V5103	SEAL-O-RING
2	8T6764	PLUG-NPTF
4	9S8752	NUT-FULL
21	9X6458	WASHER-HARD
2	1097411	SEAL-O-RING
2	1121567	STRAP
2	1223374	ELBOW-AIR INLET
4	3025889	CLAMP-V-BAND
1	3737300	PIPE-AIR
1	3737301	PIPE-AIR
2	3840516	BELLOWS AS
1	3963371	BRACKET
1	3963372	BRACKET
1	4202471	SHIELD AS
1	4202472	SHIELD AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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Replace existing air lines group with the new cast design. Refer to the attached Rework Procedure.

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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, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-hour job

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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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Disassembly

1. Remove V-Band-Clamps from Bellows Assembly, and discard clamps.

2. Remove bolts from Air Inlet Tubes that connect it to the Air-Inlet Cover and discard hardware.

3. Remove bolts from Air Inlet Bracket assembly, and discard hardware.

4. Remove Air Inlet tubes.

5. Remove Air Inlet Tube Bracket.

6. Remove Bellows Assembly.

Assembly

1. Install Plug (1) into Air Inlet Elbows (3).

2. Assemble 6V-5103 O-Ring to Air Inlet Tube LH (5) and Air Inlet Tube RH (6).

3. Lubricate the bore for the O-Rings and Air Inlet Tube LH (5) and Air Inlet Tube RH (6) with P-80 Rubber Lubricant.

4. Attach (5) and (6) Air Inlet Tubes to Elbow (3) using Strap (2) hand-tightening
with 0S-1594 Bolts and 9X-6458 Washers.

5. Connect Bellows Assembly (4) to turbo, and hand tighten with V-Band Clamps (9).

NOTE: Ensure Bellows are installed for proper flow direction as indicated on bellows by arrow.

NOTE: Apply Never-Seez Marine Grade (also called "Mariner's Choice") to the threads, bearing surfaces, and inside diameter of clamps before assembly.

6. Install 109-7411 O-Rings into both Air Inlet Elbows (3).

7. Assemble Bracket LH (8) to Air Inlet Tube LH (5) hand-tightening with 0S-1594 Bolts, and 9X-6458 Washers, and 9S-8752 Nut.

8. Assemble Bracket LH (8) to engine hand tightening with 0S-1594 Bolts and 9X-6458 Washers.

9. Assemble Bracket RH (7) to Air Inlet Tube RH (6) hand-tightening 0S-1594 Bolts, 9X-6458 Washers, and 9S-8752 Nut.

10. Assemble Bracket RH (7) to engine hand tightening with 0S-1594 Bolts and 9X-6458 Washers.

11. Assemble both Air Inlet Elbows (3) to Air Inlet Cover, and hand tighten using 0S-1588 Bolts and 5M-2894 Washers.

12. Connect Air Inlet tubes to Turbo using Bellows Assembly (4), and fasten with V-Band Clamps (9) to 7.5 +/- 1 Nm.

13. Secure all bolts and nuts for Inlet Elbows (3), Straps (2), and both (7) and (8) brackets.

14.Install new heat shields to both air tubes.