VALVE GP-RELIEF 7I7968 - Caterpillar

REBE9118-01
07Feb2013
(Revised 09Jul2013)
U-45
A-36
D-41
O-44
TM-2
Before/After
PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR LINES GROUP ON CERTAIN 3512C HD MARINE ENGINES
1071 PS43832
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 "PS43832" 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 07Feb2013 Service Letter. Changes have been made to the Parts Needed and Rework Procedure.
TERMINATION DATE
28Feb2015
PROBLEM
The existing air lines group can crack or fail on certain 3512C HD Marine Engines. If the existing air lines group fails it can cause boost leaks.
AFFECTED PRODUCT
Model Identification Number
3512C HD T3P00200-00203
T3R00202-00224
T3S00200-00203
PARTS NEEDED
Qty
Part Number Description
4 0S1571 BOLT
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 3025889 CLAMP-V-BAND
1 3737300 PIPE-AIR
1 3737301 PIPE-AIR
2 3840516 BELLOWS AS
1 3963371 BRACKET
1 3963372 BRACKET
1 4202471 SHIELD AS
1 4202472 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 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, and discard clamps.
2. Remove bolts from Air Inlet Tubes that connect it to the Air-Inlet Cover and discard hardware.
3. Remove bolts from Air Inlet Bracket assembly, and discard 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 6V-5103 O-Ring 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 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 Never-Seez Marine Grade (also called "Mariner's Choice") to the threads, bearing surfaces, and inside diameter of clamps before assembly.
6. Install 109-7411 O-Rings into both Air Inlet Elbows (3).
7. Assemble Bracket LH (8) to Air Inlet Tube LH (5) hand-tightening with 0S-1594 Bolts, and 9X-6458 Washers, and 9S-8752 Nut.
8. Assemble Bracket LH (8) to engine hand tightening with 0S-1594 Bolts and 9X-6458 Washers.
9.