Product Support Program For Repairing Cracked Exhaust Manifolds On Certain 3516 Marine Engines Caterpillar

Product Support Program For Repairing Cracked Exhaust Manifolds On Certain 3516 Marine Engines

June 1, 1999
U-154
S-91
H-61
O-136
TM-1

NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4879" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Termination Date

Problem

Cracks in the weld joint between the casting and steel outer shell of the exhaust manifold may occur on certain 3516 Marine Engines. These manifolds need to be repaired or replaced.

Affected Product
Model & Identification Number

3516 (25Z1310, 25Z1802, 25Z1805, 25Z1809, 25Z2145, 25Z2470, 25Z2557, 25Z2562, 25Z2587, 25Z2616, 25Z2619, 25Z2708, 25Z2710, 25Z2858, 25Z2884, 25Z2898, 25Z2899, 25Z2942, 25Z2993, 25Z3236, 25Z3241, 25Z3279, 25Z3287, 25Z3394, 25Z3396, 25Z3419, 25Z3427, 25Z3432, 25Z3460, 25Z3466, 25Z3562, 25Z3572, 25Z3575, 25Z3579, 25Z3585, 25Z3586, 25Z3592, 25Z3630, 25Z3634, 25Z3651, 25Z3654-3656, 25Z3680, 25Z3685, 25Z3690, 25Z3691, 25Z3694, 25Z3782, 25Z3783, 25Z3878, 25Z3882, 25Z3885, 25Z3907, 25Z3911, 25Z3914, 25Z3917, 25Z4073-4075, 25Z4077, 25Z4082, 25Z4085, 25Z4099, 25Z4100, 25Z4129, 25Z4179, 25Z4181, 25Z4298, 25Z4381, 25Z4393, 25Z4459, 25Z4460, 25Z4465, 25Z4473, 25Z4495, 25Z4499, 25Z4502, 25Z4610, 25Z4662, 25Z4874, 25Z4879, 25Z4888, 25Z4892, 25Z4896-4901, 25Z4903-4905, 25Z4997, 25Z5053, 25Z5181, 25Z5225, 25Z5239, 25Z5268, 25Z5322, 25Z5376, 25Z5423, 25Z5427, 25Z5467, 25Z5475-5477, 25Z5481-5483, 25Z5500, 25Z5506, 25Z5507, 25Z5579, 25Z5659, 25Z5734, 25Z5736, 25Z5742, 25Z5764, 25Z5782, 25Z5887, 25Z5941, 25Z5998, 25Z6023, 25Z6024, 25Z6100, 25Z6118, 25Z6131 29Z1-1338 )

Parts Needed

8 - 1B9575 Bolt

4 - 7D1649 Washer - Hard

1 - 6I0048 Manifold Assembly

1 - 6I0049 Manifold Assembly

2 - 0L2070 Bolt

4 - 5M2894 Washer - Hard

8 - 9M1974 Washer - Hard

4 - 0S1595 Bolt

2 - 9S8752 Nut

4 - 1610801 Bar

1 - 1610802 Support

1 - 1610803 Support - LH

1 - 1610804 Support - RH

Action Required

See the attached Rework Procedure.

Service Claim Allowances

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

0-5000 Hours:

Install 161802, 161803, 1610804 Supports and (4) 161801 Bars as shown in Illustration 1. Replace the exhaust manifold only if cracked.

5001-15000 Hours:

Repair the cracked exhaust manifold using SEBF8246, guideline for reusable parts salvage "Salvage Of Weld On Watercooled Exhaust Manifolds". Install the supports and adapters per above procedure install the supports and adapters per above procedure.

NOTE: 6I0048 and 6I0049 Manifolds are optional parts, to be used only if manifold is cracked. If the engine has 5000 hours or less, then the labor hours increased to 10 hours and the parts costs of the 6I0048 and 6I0049 Manifolds are covered.

1. 1610801 Bar 7. 1B9575 Bolt

2. 1610802 Support 8. 5M2894 Washer - Hard

3. 1610803 Support - LH 9. 7D1649 Washer - Hard

4. 1610804 Support - RH 10. 9M1974 Washer - Hard

5. 0L2070 Bolt 11. 9S8752 Nut - Full

6. 0S1595 Bolt

Rear View of Engine

Illustration 1