PRODUCT IMPROVEMENT PROGRAM FOR PINNING THE TURBOCHARGER HOUSING ON CERTAIN 3512C AND 3516C MARINE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR PINNING THE TURBOCHARGER HOUSING ON CERTAIN 3512C AND 3516C MARINE ENGINES

Usage:

TEBE1908-02

Show/hide table

12Nov2014

(Revised 24Feb2016)

U-668

A-498

D-591

O-581

TM-26

Show/hide table

Safety	PRODUCT IMPROVEMENT PROGRAM FOR PINNING THE TURBOCHARGER HOUSING ON CERTAIN 3512C AND 3516C MARINE ENGINES
1052 1053		PI10994

Show/hide table

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 as soon as possible. When reporting the repair, use "PI10994" 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 "PI10994" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table


NOTE:	This Revised Service Letter replaces the 12Nov2014 (Revised 17Jul2015) Service Letter. Changes have been made to the Affected Product, Parts Needed, and Service Claim Allowances.

Show/hide table

PROBLEM

Show/hide table

The existing turbocharger clamp may allow rotation of the turbo housing on some higher ratings on 3512C and 3516C Marine Engines causing a failure of the exhaust bellows, which may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
3512C	TTG00200, 211, 216-219, 243-244, 248, 253-260, 263-264, 268, 274-275, 278, 280-316, 318-340
3516C	TTJ00200, 236, 255-256, 264-267, 285-286, 294-296, 299, 303-304, 312-317, 324-325, 343-344, 350-351, 364-370, 372, 374-375, 382-383, 387, 398-399, 408, 410-411, 425, 427-429, 436-437, 447, 450-457, 459-461, 464-493

Show/hide table

*****Group 2*****
3512C	TTG00341-00371
3516C	TTJ00494-00599, 601, 604, 607

Show/hide table

*****Group 3*****
3512C HD	T3W00204-00234
3516C HD	TKT00206, 208-209, 214-243

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
2	1A2036	DOWEL
4	2432975	CLAMP-V-BAND
2	3026504	BELLOWS AS
2	3725858	CLAMP-V-BAND
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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*****
2	1A2036	DOWEL
2	3725858	CLAMP-V-BAND
4	3744581	GASKET-EXHAUST
2	3840515	BELLOWS AS
4	4784159	CLAMP-V-BAND
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 3*****
2	1A2036	DOWEL
2	3645416	BELLOWS AS
2	3725858	CLAMP-V-BAND
4	3744581	GASKET-EXHAUST
4	4501447	CLAMP-V-BAND
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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

Show/hide table

Refer to the attached Rework Procedure to properly machine a pin into the housing and install the new clamp.

Show/hide table

OWNER NOTIFICATION

Show/hide table

Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

SERVICE CLAIM ALLOWANCES

Show/hide table

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

Show/hide table

NOTE: This is a 4.0-hour job for Group 1

Show/hide table

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

Show/hide table

NOTE: This is a 4.0-hour job for Group 2

Show/hide table

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

Show/hide table

NOTE: This is a 4.0-hour job for Group 3

Show/hide table

PARTS DISPOSITION

Show/hide table

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

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

Show/hide table

EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR PINNING THE TURBOCHARGER HOUSING

MODELS INVOLVED - CERTAIN 3512C AND 3516C MARINE ENGINES

Dear Cat Product Owner:

The turbocharger needs to be reworked on the products listed below. The existing turbocharger housing can rotate, causing a failure of the exhaust bellows, which may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. You will not be charged for the service performed.

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

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the SAFETY.CAT.COM website and click on the Product Safety page for more information. Please refer the dealer to their Service Letter dated 12Nov2014 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 12Nov2014 Service Letter

Rework Procedure

Show/hide table

Apply the following procedure to both turbochargers on the engine.

1. Prior to changing out the clamps, loosen the two bellows that connect to the turbine housing so that the turbo is isolated and there is no force pulling on the turbine housing (Image1.1.1). Check that the turbo housing is aligned properly; make sure the two mating flanges are flush all the way around.

NOTE: It may be necessary to loosen the turbo cartridge bolts to allow the cartridge to move and align the cartridge flange with the turbo flange (Image1.1.2).

Image1.1.1

Image1.1.2

2. The housing must be retained while the clamp is off. Use a c-clamp to hold the housing in place (Image1.2.1).

Image1.2.1

3. Install an old v-band clamp to be modified for use as a drill guide. Fabricate the drill guide using an old v-band clamp and weld a lead boss to the old v-band clamp. Ensure this boss is centered on the old v-band clamp (Image1.3.1, Image1.3.2).

Image1.3.1

Image1.3.2

4. Set the drill guide in place for drilling. Drill a hole with a 6.5mm drill bit to a maximum drill depth of 12.5mm. The drilled hole must be centered between the flange halves on the top side of the flanges (Image1.4.1).

Image1.4.1

5. Set 1A-2036 Dowel Pin in place (Image1.5.1).

NOTE: Pin must be clearance fit, not pressed fit. The dowel should not be over a 0.5mm maximum protrusion.

Image1.5.1

6. Once the dowel pin is in place, install 372-5858 Clamp following Engine News, SEBD9761, "A New Band Clamp Is Available for Turbochargers on Certain 3500 and C175-16 Engines" (Image1.6.1, Image1.6.2).

Refer to the Disassembly and Assembly for the engine for the procedure to install the 302-6504 Bellows Assembly.