Product Support Program For Updating Turbocharger And Related Components On Certain 3516 Marine Engines With EUI Caterpillar

Product Support Program For Updating Turbocharger And Related Components On Certain 3516 Marine Engines With EUI

Usage:

Product Support Program For Updating Turbocharger And Related Components On Certain 3516 Marine Engines With EUI

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SMCS -	1052	PS40094

March 16, 2000
U-90
AU-53
H-27
O-77
TM-2

NOTE: This Program can 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 "PS40094" as the Part number and "7755" as the Group Number. If adminstered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If adminstered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Termination Date

March 31, 2001

Problem

Certain 3516 Marine Engines with EUI may leak exhaust at the turbocharger to exhaust elbow joint and may have short turbocharger life due to compressor wheel blade fatigue.

Affected Product
Model & Identification Number

Group 1

(3516 wtih rated speed 1600 rpm)

3516 (3SS297, 3SS300-302, 3SS304-307, 3SS315, 3SS320)

Group 2

(3516 with rated speed 1800 rpm)

3516 (3SS298-299, 3SS303, 3SS308-314, 3SS316-317, 3SS319, 3SS321-322)

Parts Needed

12 - 1A2029 BOLT

21 - 1A2029 BOLT

8 - 3B1915 BOLT

32 - 8C8491 WASHER-HARD

1 - 6H1717 BOLT

6 - 6H1717 BOLT

16 - 7L6443 BOLT

20 - 5M2894 WASHER-HARD

35 - 5M2894 WASHER-HARD

8 - 2N2765 BOLT

2 - 8N5254 HOSE-REDUCER

2 - 5P3860 CLAMP-HOSE

2 - 5P4869 CLAMP-HOSE

10 - 5P6025 WIRE-LOCK

6 - 5P8245 WASHER-HARD

4 - 0S1591 BOLT

4 - 0S1594 BOLT

4 - 9S8752 NUT-FULL

1 - 8T6765 PLUG-PIPE

2 - 1215736 GASKET-TURBO

1 - 1221681 SUPPORT AS

4 - 1406461 GASKET-EX

4 - 1406462 FLANGE-HALF

1 - 1467639 HOSE AS

1 - 1490233 PIPE (RH)

1 - 1520467 BRACKET AS

1 - 1520469 BRACKET

1 - 1520472 BRACKET AS

2 - 1625721 BELLOWS AS

4 - 1625722 FLANGE-HALF

1 - 1627686 BRACKET AS-L

1 - 1627689 SUPPORT AS

1 - 1628864 ELBOW-TURBO

1 - 1628865 MANIFOLD-EX

1 - 1634270 BRACKET AS

1 - 1640866 PIPE (LH)

1 - 1665932 TUBE AS

1 - 1665934 TUBE

1 - 1665935 TUBE AS

1 - 1665938 SHIELD AS

8 - 1687800 LOCKNUT

2 - 1832822 TURBOCHARGER (Group 1 Only)

2 - 1832825 TURBOCHARGER (Group 2 Only)

OPTIONAL REPAIR PARTS:

QUANTITY 1 OF 12" TO 14" EXHAUST ADAPTER - 1W7996

Action Required

COMPLETING THE UPDATE IN THIS PROGRAM MAKES THE FOLLOWING CHANGES TO THE EXHAUST OUTLET ELBOW:

* OUTLET DIAMETER INCREASES FROM 203 MM TO 305 MM.

* HORIZONTAL PLANE OF OUTLET FLANGE RAISES 120 MM.

* FORE-AFT CENTERLINE OF OUTLET MOVES 75 MM REARWARD.

1. Remove engine air cleaners and air cleaner mounting brackets. The air cleaners do not change in this update therefore they will be reused.

2. Remove the Exhaust Manifold Softwrap (135-6901) from exhaust manifold casting connecting left hand exhaust maniold to left hand turbine housing.

3. Remove left hand Turbo Oil Drain Line (113-4646) and left hand Turbo Oil Supply Line (113-4642).

4. Remove left hand Turbo Water Supply Line (139-1577) and left hand Turbo Water Return Line (113-4645).

5. Remove right hand and left hand Air Lines (136-9627 and 136-9626).

6. Remove Exhaust Elbow (147-6618)

7. Remove entire Turbocharger Group (159-6085)

8. Remove rear left hand Exhaust Manifold Casting (125-9754) and left hand Exhaust Manifold Support Bracket (8N-8820)

9. Other components may need to be removed to make removal and installation of parts listed possible. The parts listed above will not be reused.

10. Install new left hand Exhaust Manifold Casting (162-8865) and left hand Exhaust Manifold Support Bracket (163-4270)

11. Install entire Turbocharger Group (183-2822 for 1600 rpm engines or 183-2825 for 1800 rpm engines)

12. Install Exhaust Elbow (162-8864)

13. Install right hand and left hand Air Lines (149-0233 and 164-0866)

14. Install left hand turbo Water Supply Line (166-5935) and left hand turbo Water Return Line (146-7639)

15. Install left hand Turbo Oil Drain Line (166-5924) and left hand Turbo Oil Supply Line (166-5932).

16. Install the Exhaust Manifold Softwrap(166-5938) around exhaust manifold casting connecting left hand exhaust manifold to left hand turbine housing.

17. Install entire engine Air Cleaner Mounting Group (162-7687).