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

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

Usage:

TEBE1933-02

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19Feb2015

(Revised 20Nov2015)

U-71

A-52

D-66

O-65

TM-1

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Before/After	PRODUCT SUPPORT PROGRAM FOR PINNING THE TURBOCHARGER ON CERTAIN 3512C AND 3516C MARINE ENGINES
1052		PS44648

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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 "PS44648" 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 19Feb2015 (Revised 08Sep2015) Service Letter. Changes have been made to the Affected Product and Service Claim Allowances.

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TERMINATION DATE

28Feb2017

PROBLEM

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The existing turbocharger clamp may allow rotation of the turbo housing on certain 3512C and 3516C Marine Engines causing a failure of the exhaust bellows.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3512C HD	T3Y00200 TKP00200-00231
3516C HD	TKR00200-00213 TKS00204-00207, 212, 214-227 TKX00200-00205 TKY00228-00288, 290-353

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*****Group 2*****
3512C	SLM00119, 129, 135-136, 160, 163-165, 167, 184, 228-229, 231, 244-246, 257, 274, 276, 313, 317, 319-320, 330-331, 333-338, 343-345, 351, 359, 364, 373-377, 384, 387-390, 396-397, 400-403, 406-408, 418-424, 426, 437-440, 445-448, 451, 453, 456-459, 473-502, 504-544, 549-572, 577, 581-587, 590, 593-600
3512C HD	BC200101-00123, 125-141, 144-146
3516C	JTS00117-00121, 139, 148-150, 153, 195, 199, 216, 230, 232, 234-237, 245-246, 249-251, 255, 257-258, 262-263, 269, 289, 291-293, 295, 297, 302, 304-305, 309-312, 319-320, 324, 333-344, 348-352, 354-356, 358, 360, 362-365, 369, 375-389, 392-404, 407-439, 448-452, 457-463, 468-481, 486-491 TTH00210, 213, 218-219, 222, 224, 229, 240-241, 257, 264, 315-318, 320, 322-323, 328-329, 331-332, 348, 353-359, 363, 366-367, 370-371, 385, 392, 411-412, 414, 427-430, 437-440, 444-446, 450, 454, 456-460, 462, 464-467, 472-474, 484, 487-488, 491, 493, 507-511, 515, 517, 528-529, 534, 537, 540-541, 544-546, 549-551, 554-561, 568-583, 589, 591, 593, 595-601, 608-612, 615-619, 621-622, 627-642, 644, 646-696, 698-958, 960
3516C HD	BC300100-00121

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	1A2036	DOWEL
2	3645416	BELLOWS AS
2	3725858	CLAMP-V-BAND
2	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 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.
*****Group 2*****
2	1A2036	DOWEL
2	3725858	CLAMP-V-BAND
4	3744581	GASKET-EXHAUST
2	3840515	BELLOWS AS
4	3840519	CLAMP-V-BAND
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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Refer to the attached Rework Procedure to properly machine a pin into the housing and install the new clamp.

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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%
*****Group 1*****
0-1000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 12.0-hour job for Group 1

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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*****
0-1000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 12.0-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

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.