PRODUCT SUPPORT PROGRAM FOR REWORKING THE AFTERCOOLER PIPING ON CERTAIN 3612, 3616, C280-12, AND C280-16 ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE AFTERCOOLER PIPING ON CERTAIN 3612, 3616, C280-12, AND C280-16 ENGINES

Usage:

REBE8529-01

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12Jul2012

(Revised 10Sep2012)

U-370

A-294

D-322

O-339

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE AFTERCOOLER PIPING ON CERTAIN 3612, 3616, C280-12, AND C280-16 ENGINES
1063		PS52256

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52256" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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 12Jul2012 Service Letter. Changes have been made to Title, Problem, Affected Product, Parts Needed, and Service Claim Allowances.

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TERMINATION DATE

31Jul2014

PROBLEM

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The existing 255-5544 Tube used in 179-9333 and 185-5775 Aftercooler Groups can fail on certain 3612, 3616, C280-12, and C280-16 Engines. The existing water lines may leak.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3612	9RC00455, 457-461, 465-467, 472, 475-476, 478-480, 482-484, 487, 492-493, 496-497, 512-514, 520-521, 533
3616	1PD00454-00455, 457-462, 464, 466-467, 469-473, 480, 483, 489-490, 495-497, 499-500, 502-505, 507-512, 527-529, 533-539, 541-542, 544-545, 548, 550-552, 554, 556, 565-567, 570-573, 575-576, 578-583, 596-617, 635, 637, 640, 642-643, 645, 647-648, 650, 652, 665-666, 686-687, 689, 691-692, 694, 698-700

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*****Group 2*****
3612	9RC00462-00464, 468-469, 473, 486, 498-501, 515-519, 522-532, 534-538
3616	1PD00456, 468, 474-476, 478, 484, 486-487, 492-494, 498, 501, 506, 513-526, 530-532, 540, 543, 546-547, 549, 553, 555, 557-564, 568-569, 574, 577, 584-595, 618-634, 636, 638-639, 641, 644, 646, 649, 651, 653-664, 667-685, 688, 690, 693, 695-697
C280-12	TSJ00112, 115-119
C280-16	NKB00148 TDX00133-00135, 150

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
3	0L1143	BOLT
4	0S1571	BOLT
4	0T0065	BOLT
11	3V3308	WASHER-HARD
1	6V5066	SEAL-O RING
1	6V5504	SEAL-O-RING
3	6W6672	SPACER
4	7C9560	SPACER
4	8T4985	CLAMP-BAND
1	1100096	RING
1	3696019	TUBE
18	3718950	HOSE-BULK (18 cm)
1	3791581	ELBOW
1	3791583	PLATE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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.
*****Group 2*****
3	0L1143	BOLT
4	0S1571	BOLT
4	0T0065	BOLT
11	3V3308	WASHER-HARD
1	6V5066	SEAL-O RING
1	6V5504	SEAL-O-RING
3	6W6672	SPACER
4	7C9560	SPACER
4	8T4985	CLAMP-BAND
1	1100096	RING
1	3696019	TUBE
18	3718950	HOSE-BULK (18 cm)
1	3791581	ELBOW
1	3791583	PLATE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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After failure, refer to the attached Rework Procedure.

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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*****
0-7500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.5-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*****
0-7500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.5-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

Perform all steps necessary to prepare the engine for safely replacing the aftercooler water piping.

1) Remove the 255-5544 Tube, 282-2462 Bracket Assembly, 131-5499 Flange, 263-1809 Hump Hose, 255-5543 Tube, and all related mounting hardware.

NOTE: Keep all the 108-6170 Clamps for reuse. The forward mounted 152-3727 Bracket will not be reused.

Image1.1.1

2) Install the 6V-5504 O-ring Seal onto the 379-1581 Elbow and install the elbow using four 0S-1571 Bolts with four 3V-3308 Washers.

3) Install the 7C-7534 Hose and four 8T-4985 Clamps. Do not tighten the clamps.

Image1.2.1

4) Install the 379-1583 Bracket using three 0L-1143 Bolts, three 3V-3308 Washers, and three 6W-6672 Spacers. Refer to Image1.5.1 for the location on left front aftercooler cover.

Image1.3.1

5) Install the 6V-5066 O-ring Seal and 110-0096 Ring onto the 369-6019 Tube.

6) Install the straight end of the tube into the aftercooler elbow and 90 degree elbow end into the hose at the front of aftercooler.

Image1.5.1

7) Reinstall the 108-6170 Clamps at rear of tube using existing hardware.

Image1.6.1

8) Install the 108-6170 Clamps using four 0T-0065 Bolt, four 3V-3308 Washers, and four 7C-9560 Spacers.

9) Position the 7C-7534 Hose evenly between cast elbow and tube at front of aftercooler.

10) Tighten the four 8T-4985 Clamps securing hose to elbow and tube.