ROLLER GP-TRACK-SINGLE FLANGE 6Y2795 - Caterpillar

REBE9795-01
02Oct2013
(Revised 01Oct2014)
U-470
A-424
D-510
O-485
TM-21
Before/After
PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR LINES GROUP ON CERTAIN 3512C HD, AND 3516C HD MARINE ENGINES
1071 PS44039
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.
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 "PS44039" as the Part Numberand "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.
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.
This Revised Service Letter replaces the 02Oct2013 Service Letter. Changes have been made to the Mail Codes.
TERMINATION DATE
31Oct2015
PROBLEM
The existing air lines group can crack or break on certain 3512C HD, and 3516C HD Marine Engines. If the existing air lines group failes it can cause boost leaks.
AFFECTED PRODUCT
Model Identification Number
3512C HD T3W00202-00203
3516C HD TKR00200-00201
TKS00202-00207, 210-211
TKT00200-00205
TKY00208-00211, 216-223
PARTS NEEDED
Qty
Part Number Description
4 0S1571 BOLT-HEX HEAD
8 0S1588 BOLT
13 0S1594 BOLT
8 5M2894 WASHER-HARD
4 6V5103 SEAL-O-RING
2 8T6764 PLUG-NPTF
4 9S8752 NUT-FULL
21 9X6458 WASHER-HARD
2 1097411 SEAL-O-RING
2 1121567 STRAP
2 1223374 ELBOW-AIR INLET
4 2432975 CLAMP-V-BAND
2 3440079 BELLOWS AS
1 3737302 PIPE-AIR (LH)
1 3737303 PIPE-AIR
1 3963369 BRACKET
1 3963370 BRACKET
1 4307895 SHIELD AS
1 4385469 SHIELD AS
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
Replace the existing air lines group with the new cast design. Refer to the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-4000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Disassembly
1. Remove V-Band-Clamps from Bellows Assembly. Do not reuse the clamps.
2. Remove bolts from Air Inlet Tubes that connect it to the Air-Inlet Cover. Do not reuse the hardware.
3. Remove bolts from Air Inlet Bracket assembly. Do not reuse the hardware.
4. Remove Air Inlet tubes.
5. Remove Air Inlet Tube Bracket.
6. Remove Bellows Assembly.
Assembly
1. Install plug (1) into Air Inlet Elbows (3).
2. Assemble O-Ring 6V-5103 to Air Inlet Tube LH (5) and Air Inlet Tube RH (6).
3. Lubricate the bore for the O-Rings and Air Inlet Tube LH (5) and Air Inlet Tube RH (6) with with P-80 Rubber Lubricant.
4. Attach (5) and (6) Air Inlet Tubes to Elbow (3) using Strap (2) hand-tightening with 0S-1594 bolts and 9X-6458 Washers.
5.Connect Bellows Assembly (4) to turbo, and hand tighten with V-Band Clamps (9).
Ensure Bellows are installed for proper flow direction as indicated on bellows by arrow.
Apply