PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXPANSION TANK MOUNTING BRACKET ON CERTAIN 3516B MARINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXPANSION TANK MOUNTING BRACKET ON CERTAIN 3516B MARINE ENGINES

Usage:

TEBE4540-01

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26Jul2016

(Revised 29Jul2016)

N030
N084

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After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXPANSION TANK MOUNTING BRACKET ON CERTAIN 3516B MARINE ENGINES
1354		PS53260

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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 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 "PS53260" 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.

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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 26Jul2016 Service Letter. A change has been made to the Service Claim Allowances.

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TERMINATION DATE

31Jul2018

PROBLEM

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The existing mounting bracket can fail due to stress cracks initiating at the welded structures on certain 3516B Marine Engines.

AFFECTED PRODUCT

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Model	Identification Number
3516B	S2X00323, 326-330, 335-340, 750-753

PARTS NEEDED

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Qty	Part Number	Description
1	1F7958	NUT-FULL
1	1W8793	SPACER
2	2N0931	GASKET
1	3H5939	GASKET-HEAT EXCH
4	3J1907	SEAL-O-RING-STOR
4	4W0530	RING-RETAINING
2	6V1454	SEAL-O-RING
2	6V5066	SEAL-O-RING
1	6V6809	SEAL-O-RING
1	6V9027	SEAL-O-RING
2	7D1649	WASHER-HARD
6	7E6016	GASKET AS
2	7E7209	RING-RETAINER
1	7N4927	GASKET-HSG COVER
1	7X7906	CLIP
1	7X7907	CLIP
6	8T1919	SEAL-O-RING
2	1100096	RING
2	1673884	BOLT-HEX HEAD
1	2416236	GASKET
1	2416476	GASKET
1	3678480	GROMMET
2	4835703	BRACKET
1	4843039	TANK AS
1	4978166	TUBE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% 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 the existing mounting bracket with the new expansion tank assembly. The new tank assembly has an improved weld structure that results with increased service life and is more resistant to fatigue. Please reference SEBU7844 under the cooling system section in the OMM for depressurizing, draining, flushing and filling the system.

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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%
0-3000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-25000 hrs, 13-144 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

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NOTE: This is a 6.0-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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Drain coolant from system according to OMM ? SEBU7844 Coolant Change
Remove the filler neck assembly and install lifting eyes
Install lifting device to support weight of tank during disassembly

Image1.1.1

Drain seawater from auxiliary seawater circuit
Remove seawater pump outlet tube (light blue 1.2.1)
Remove the seawater return adapter from the heat exchanger (magenta 1.2.2)

Image1.2.1

Image1.2.2

Remove the jacket water bypass tube (blue) from the thermostat housing and the water pump
Remove the SCAC supply tube (yellow) from the bottom of the expansion tank and the SCAC thermostat manifold
Remove the expansion tank jumper tube (red) from the expansion tank and the thermostat housing

Image1.3.1

Image1.3.2

Turn the fuel supply to the OFF position
Drain fuel into appropriate container
Remove fuel priming pump lines (green) from back of expansion tank

Image1.4.1

Remove the fuel cooler supply line from side of the heat exchanger (green) and the customer fuel supply (red circle)

Image1.5.1

Image1.5.2

Verify that expansion tank is properly supported with lifting device, and remove the 10 bolts attaching it to the block(orange). Set expansion tank on ground by setting blocks under the heat exchanger

Image1.6.1

Image1.6.2

Remove the retaining bolts for the tubes on the rear of the expansion tank
Remove the bolts holding the castings to the rear of the expansion tank and remove the castings and tubes

Image1.7.1

Remove the fuel priming pump from rear of expansion tank (purple)

Image1.8.1

Remove the 6 bolts, 3 per side, (orange) that hold the heat exchanger to the expansion tank. Set the expansion tank to the side

Image1.9.1

Reverse process of disassembly, torque all fasteners and other threaded components per SIS guidelines
Remove the two purple bolts and washers shown below from the heat exchanger front plate

Image1.10.1

Loosely assemble (finger tight) two brackets 483-5703 (green) with 0S1585 bolts and 7D1649 washers (pink) and front plate bolts and washers (purple) removed in the previous step

Image1.11.1

Tighten 0S1585 bolts (pink) to 105 +/- 20 Nm
Tighten front plate bolts (purple) to 150 +/- 7 Nm

Image1.12.1

Fill coolant according to OMM ? SEBU7844 Coolant Change
Leak test the coolant system according to OMM - RENR5078 Testing the Coolant System for Leaks
Perform visual inspection according to OMM ? KENR5403 Visual Inspection