PRODUCT SUPPORT PROGRAM FOR UPDATING THE OIL MIST DETECTOR ON MARINE AND PETROLEUM 3616 AND C280-16 ENGINES Caterpillar
PRODUCT SUPPORT PROGRAM FOR UPDATING THE OIL MIST DETECTOR ON MARINE AND PETROLEUM 3616 AND C280-16 ENGINES
Usage:
REBE7902-02
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14Jun2012
(Revised 05Aug2013)
U-318
A-253
D-275
O-289
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Before/After
PRODUCT SUPPORT PROGRAM FOR UPDATING THE OIL MIST DETECTOR ON MARINE AND PETROLEUM 3616 AND C280-16 ENGINES
1300 1336 1071
PS43627
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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 "PS43627" 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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NOTE:
This Revised Service Letter replaces the 14Jun2012 (Revised 03Dec2012) Service Letter. Changes have been made to the Affected Product and Service Claim Allowances.
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TERMINATION DATE
30Jun2014
PROBLEM
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The existing 191-6500 Oil Mist Detector (OMD) group is susceptible to frequent false positive shutdowns causing the engine to shutdown without warning.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 28% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 28% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 28% 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
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Groups 1 and 2 require side covers to be reworked for use with the updated oil mist detection system while Group 3 does not, see Image1 for machining specifications. Group 1 has rear mounted turbos and requires 5 side covers to be reworked. Group 2 has front mounted turbos and requires 4 side covers to be reworked. A limited number of spare covers are available upon request and will be exchanged with the side covers removed during the upgrade. Contact Customer Service for more information. For Marine Engines, contact Steve Hoffman at 765-448-2452 or Hoffman_Steve_W@cat.com. For Petroleum Engines, contact Brad Devorak at 765-448-5046 or Devorak_Brad_C@cat.com.
Refer to Hydraulic Information System (HIS) to build the hose assemblies that are listed in the Parts Needed.
Refer to the attached Rework Procedure.
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Image1
SERVICE CLAIM ALLOWANCES
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-200000 hrs, 0-168 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 10.0-hour job for Group 1
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-200000 hrs, 0-168 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 10.0-hour job for Group 2
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-200000 hrs, 0-168 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 10.0-hour job for Group 3
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Group 1 - Ensure that five engine side covers per engine being updated are reworked prior to starting this rework procedure to the oil mist detector system. Reference the 421-6504 Oil Mist Detector Group and the 371-7605 Air Lines Group.
Group 2 - Ensure that four engine side covers per engine being updated are reworked prior to starting this rework procedure to the oil mist detector system. Reference the 421-6503 Oil Mist Detector Group and the 372-5028 Air Lines Group.
Group 3 - No engine side covers require rework prior to starting this rework procedure to the oil mist detector system. Reference the 368-5088 Oil Mist Detector Group and the 372-5028 Air Lines Group.
- 1) Remove the current exhaust hose from the outlet of the OMD (dispose of the hose but keep the hardware for reuse).
- 2) Remove the 2 hoses connected between the manifolds and the OMD (dispose of the hoses but keep all hardware for reuse).
- 3) Carefully disconnect the hose and tube from the 144-0526 Pressure Regulator (both will be reused) and disconnect the tube from the other pressure regulator (this regulator will not be reused).
Image1.2.1
- 4) Remove and discard the hose connected between the supply air tube and 144-0526 Pressure Regulator.
- 5) Remove the pressure regulators from the OMD support bracket (dispose of the larger pressure regulator but keep the smaller 144-0526 Pressure Regulator for reuse). Inspect 144-0526 Pressure Regulator for corrosion and replace as needed.
- 6) Remove the oil collection box and discard.
Image1.3.1
Image1.3.2
- 7) Remove bolts and P-clips supporting the manifolds (remove the P-clips carefully for reuse, the bolts will not be reused).
- 8) Loosen the 192-1405 Nut on each of the suction tubes and carefully remove and discard both manifolds. The 192-1406 Ferrules will not be able to be removed and will not be reused along with the nut and manifolds.
Image1.4.1
Image1.4.2
- 9) Carefully remove the explosion relief valves from these five covers and set aside for reuse. Remove all eight covers from this side of the engine to gain access to the suction funnels located in each compartment of the crankcase.
Image1.5.1
Image1.5.2
- 10) Carefully loosen the connections between the suction funnels and the block. Rotate each as shown in Image1.6.2 with the opening of the suction funnel at either the 4 o' clock position or the 8 o' clock position. The suction funnel openings will be pointed away from the main bearing webs. Tighten to 35+/-5 N.m.
Image1.6.1
Image1.6.2
For Group 1 - 11) Install the reworked explosion relief valve covers in the five locations shown in Image1.7.1 with the machined port positioned in the lower left as shown in Image1.7.2. Install the explosion relief valves removed earlier. Replace the two bolts that mounted the oil collection box with four 0S-1591 Bolts. Reinstall the remaining three crankcase covers that were removed earlier.
For Group 2 - 11) Install the reworked explosion relief valve covers in the four locations shown in Image1.7.2 with the machined port positioned in the lower left as shown in Image1.7.4. Install the explosion relief valves removed earlier. Replace the two bolts that mounted the oil collection box with four 0S-1591 Bolts. Reinstall the remaining three crankcase covers that were removed earlier. Install 370-4569 cover in forward most position, see Image1.7.2 and Image1.7.5.
For Group 3 - 11) Install new 370-4569 side covers in all positions except the right most position which will reuse one blank side cover, see Image1.7.3. Replace the two bolts that mounted the oil collection box with four 0S-1591 Bolts. Install 418-9734 covers, see Image1.7.3 for location and Image1.7.5 for hardware. Install explosion relief valves, see Image1.7.3 for location and Image 1.7.6 for hardware.
Image1.7.1
Image1.7.2
Image1.7.3
Image1.7.4
Image1.7.5
Image1.7.6
- 12) Using 371-7602 Bracket and 371-7603 Bracket, mount the 144-0526 Regulator. Note new orientation of regulator, see Image1.8.1.
For Group 1 - 14) Remove 192-1406 Ferrules and 192-1405 Nuts from 192-1404 union fittings. Install the 368-3963 Right Manifold and 368-3964 Left Manifold using eight 192-1406 Ferrules and 192-1405 Nuts, see Image1.9.1 and Image1.9.2.
For Group 2 - 14) Remove 192-1406 Ferrules and 192-1405 Nuts from 192-1404 union fittings. Install the 368-3963 Right Manifold and 421-6502 Left Manifold using eight 192-1406 Ferrules and 192-1405 Nuts, see Image1.9.1 and Image1.9.3.
For Group 3 - 14) Remove 192-1406 Ferrules and 192-1405 Nuts from 192-1404 union fittings. Install the 368-3963 Right Manifold and 421-6502 Left Manifold using eight 192-1406 Ferrules and 192-1405 Nuts, see Image1.9.1 and Image1.9.4.
- 15) Install the new 368-5083 Manifold Support Brackets and the P-clips removed earlier.
- 16) Install the new 368-5084 Hoses between the manifolds and OMD using the parts set aside for reuse earlier.
Group 1 and 2 - 17) Install the new 368-5085 Hose between the exhaust of the OMD and the port on the new explosion relief valve cover.
Group 3 -17) Install the new 390-6827 Hose between the exhaust of the OMD and the port on the new explosion relief valve cover.
Image1.9.1
Image1.9.2
Image1.9.3
Image1.9.4
- 18) Mount engine wall connections into the G3/4" side cover ports and tighten to 110 N.m.
- 19) Mount the pipe siphon into the wall connection.
- 20) Fill the siphon with 70 mL of engine oil.
- Caution, overfilling siphon can cause a draining affect causing improper operation.
Image1.10.1
For Group 1 - 21) Install 368-8023 Drain Hose, 368-8024 Drain Hose, and 368-8025 Drain Hose for the pipe siphon.
For Group 2 - 21) Install 368-8023 Drain Hose, 368-8024 Drain Hose, and 368-8025 Drain Hoses for the pipe siphon.
For Group 3 - 21) Install 419-9782 Drain Hoses, and 390-6826 Drain Hoses for the pipe siphon.
Image1.11.1
Image1.11.2
Image1.11.3
- 22) Calibrate the OMD head. Refer to RENR2225, Testing and Adjusting, "Commissioning Procedure" for Oil Mist Detectors.