Product Supprot Program for Installation of an inner shield to the exhaust manifold for certain 3500B Engines Caterpillar

Product Supprot Program for Installation of an inner shield to the exhaust manifold for certain 3500B Engines

Usage:

SEBE9949-00

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09Jun2006

L044
L120
L127
L323

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Before/After (Limited distribution)	PRODUCT SUPPROT PROGRAM FOR INSTALLATION OF AN INNER SHIELD TO THE EXHAUST MANIFOLD FOR CERTAIN 3500B ENGINES
1067		PS42215

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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 "PS42215" 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

30Jun2008

PROBLEM

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The failure of the exhaust bellows is caused by contact with the inner insulation of the hard shell heat shield, resulting in wear of the bellows convolute material until an exhaust leak path is formed.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3508B	3DM00504-00505 S2B00168-00169, 206-210, 212, 215-216, 227, 253, 265-267, 269-270 S2D00144-00145 S2E00241, 326, 328, 342-343, 357, 359, 400, 433

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*****Group 2*****
3516B	9AN00395-00396 S2R00155-00157, 164, 174-175 S2S00160, 162, 183, 202-203 S2X00263, 299-300, 307-308, 325, 331-334, 341-348, 353-361, 366-370, 387

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*****Group 3*****
3512B	S2G00100 S2H00165-00166, 200-201 S2J00241-00243, 245, 253, 262, 264-266, 268, 271, 276, 281-283, 286-289, 299-300, 303 S2K00195-00200, 203-204 S2L00222-00223, 257, 277-279, 311, 324-325, 343, 347, 361, 382-384, 432-435, 440

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	2860284	SHIELD
*****Group 2*****
2	2860285	SHIELD
*****Group 3*****
2	2843920	SHIELD

ACTION REQUIRED

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The fix for this issue consists of an internal shield that fits between the exhaust manifold and the hard shell heat shield, providing support for the insulation inside the hard shell heat shield.

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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*****
0-6000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-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*****
0-6000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 2

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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 3*****
0-6000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 3

PARTS DISPOSITION

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

Rework Procedure

Two inner shields are needed for each engine. One inner shield is used for each exhaust manifold. The new inner shields are used with the existing exhaust manifold shield.

Image1.1.1

For detailed information regarding the removal and installation of components, refer to Disassembly and Assembly, SENR6564.

1. Remove the soft shields from the exhaust manifold that is connected to the turbocharger inlet. Remove existing exhaust manifold shield (1) from the exhaust manifold.

Image1.3.1

3. Install new inner shield (2) on the exhaust manifold.

Note: The new inner shields include locating tabs on each end in order to assist with locating the shield during assembly. The locating tabs prevent the inner shields from sliding forward or frim sliding rearward during normall operation.

Note: Fasteners are not necessary for use with the new inner shields.

4. Install exhaust manifold shield (1) over new inner shield (2).

5. Reinstall the soft shields to the turbocharger inlet and the exhaust manifold shield to the exhaust manifold.