PRODUCT SUPPORT PROGRAM FOR REWORKING THE TURBO EXHAUST MANIFOLD AND TURBO BELLOWS ON CERTAIN 3512C AND 3516C MARINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE TURBO EXHAUST MANIFOLD AND TURBO BELLOWS ON CERTAIN 3512C AND 3516C MARINE ENGINES

Usage:

TEBE0022-00

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07Oct2013

U-485

D-400

O-405

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE TURBO EXHAUST MANIFOLD AND TURBO BELLOWS ON CERTAIN 3512C AND 3516C MARINE ENGINES
1059 1061		PS44047

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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 "PS44047" 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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TERMINATION DATE

31Oct2015

PROBLEM

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The existing manifold and bellows can leak exhaust due to turbo housing rotation on certain 3516C, and 3512C Marine Engines.

AFFECTED PRODUCT

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Model	Identification Number
3512C	TTG00267-00270
3516C	TTJ00264-00267, 273, 300-302, 318-325, 328-333, 338-339, 378-381, 388-395, 414, 416, 418, 421-423, 430-435, 438-439, 441-443, 446, 448-449, 462-463

PARTS NEEDED

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Qty	Part Number	Description
4	1W4658	CLAMP-V-BAND
4	4P7680	SPACER-HIGH TEMP
8	5M2894	WASHER-HARD
8	9L7373	BOLT-HIGH TEMP
4	2254340	CLAMP
2	2305021	BELLOWS AS
2	2393922	BELLOWS AS
4	3744581	GASKET-EXHAUST
2	3840515	BELLOWS AS
4	3840519	CLAMP-V-BAND
4	3977255	GASKET-EXHAUST
1	4155962	MANIFOLD-EXHAUST
1	4155964	MANIFOLD-EXHAUST
4	4205734	GASKET
2	4205735	GASKET
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.

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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%
0-15000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 8.0-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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Refer to the Disassembly and Assembly, KENR6055 for reworking the turbo exhaust manifold and bellows.

Image1.1.1

Refer to Image 1.2.1. After removing all existing components from the engine, sub assemble the parts to the 415-5962 and 415-5964 Exhaust Manifolds.
1. 420-5735 C-Ring gasket
2. 397-7255 C-ring gasket
3. 374-4581 Full marmon gasket
4. 420-5734 C-ring gasket

Image1.2.1

Refer to Image 1.3.1. Sub assemble the parts to the 230-8165 and 230-8163 Exhaust Manifolds.
1. Two 397-7255 C-ring gaskets

Image1.3.1

Refer to Image 1.4.1. Install the following parts:
1. 374-4581 Full marmon gasket
2. 420-5734 C-ring gasket

Image1.4.1

Refer to Image1.5.1. Install the following parts:
1. 384-0515 Bellows and 384-0519 V-band clamp
2. 239-3922 Bellows and 1W-4658 V-band clamp
Ensure the bellows are installed for proper flow direction as indicated by arrow on bellows

Image1.5.1

Refer to Image 1.6.1. Install the following parts:
1. 415-5962 and 415-5964 Exhaust Manifolds sub assembled with seals.
2. Align and connect manifolds to the 384-0515 Bellows using 384-0519 V-band clamps and to 239-3922 Bellows with 1W-4658 V-band clamps.

Image1.6.1

Refer to Image 1.7.1. Install the following parts:
1. 230-8165 and 230-8163 Exhaust Manifolds sub assembled with seals.
2. 230-5021 Bellows using 225-4340 V-band clamps.
Ensure bellows are installed for proper flow direction as indicated by arrow on bellows.