PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBO OIL SUPPLY HOSE ON CERTAIN C7.1 GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBO OIL SUPPLY HOSE ON CERTAIN C7.1 GENERATOR SETS

Usage:

TEBE3511-00

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27Jan2016

U-47

A-40

D-47

O-43

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBO OIL SUPPLY HOSE ON CERTAIN C7.1 GENERATOR SETS
1052 1307		PI32597

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NOTE:

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.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32597" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI32597" as the Part Number, "7751" as the Group Number, "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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COMPLETION DATE	TERMINATION DATE
31Jul2016	31Jan2017

PROBLEM

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The turbo oil supply hose needs to be replaced on certain C7.1 Generator Sets. The existing turbo oil supply hose can leak oil from the connector ferrule.

AFFECTED PRODUCT

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Model	Identification Number
C7.1	ECW00104-00105, 110-117, 120, 125, 128, 130, 132-134, 136-164, 167-169, 171, 177 GTP00104, 106-107, 110-112, 132

PARTS NEEDED

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Qty	Part Number	Description
1	4565183	LINE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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1) Ensure the generator set is switched off and the battery is isolated. Wait for the engine to cool down if the generator set has been operating. This will reduce the risk of burn injury occurring while working near the turbo. Refer to the Safety section of the Operation and Maintenance Manual and ensure that all Safety recommendations are followed.

2) Drain the oil from the engine according to the instructions shown in the engine Operation and Maintenance Manual.

3) Refer to Image1. Unscrew the banjo bolt (1) securing the oil supply hose (2) to the turbo.

4) Refer to Image2 and Image3. Unscrew the bolt (3) securing the turbo oil supply hose (2) to the engine block.

5) Remove the turbo oil supply hose. Note: Retain the quantity 2 copper washers and the quantity 1 rubber seal, for further use with the new replacement turbo oil supply hose.

6) Refer to Image4. Examine the new replacement turbo oil supply hose (4) and check that it is free from any damage or deformation.

7) Examine the oil gallery of the engine block, and the turbo, for any contamination with dirt or debris. Carefully remove any dirt or debris found with a clean cloth.

8) Refer to Image5. Add some lubricant to the turbo oil supply orifice in the engine block (5) before the new oil supply hose is installed.

9) Install the new turbo oil supply hose in position on the engine.

10) Ensure quantity 1 copper washer is located underneath the hose connector at the entry to the turbo, and quantity 1 copper washer is located underneath the head of the banjo bolt at this location.

11) Ensure quantity 1 rubber seal is installed to the groove of the oil supply hose connector where it enters the engine block.

12) Refer to Image6. Tighten the banjo bolt on the oil supply hose (6) to secure it to the turbo. Apply a torque of 33+/-3 Nm to this bolt.

13) Refer to Image7. Tighten the bolt on the turbo oil supply hose (7) to secure it to the engine block. Apply a torque of 22+/-3 Nm to this bolt.

14) Refer to Image8. Make sure the turbo oil supply hose is positioned vertically in line with the turbo.

15) Refer to Image8. Ensure the sides of the oil supply hose do not contact the body of the turbo.

16) After completing this assembly, re-fill the engine with oil and reconnect the battery.

17) Run the generator set without load for a few minutes and monitor all parts of the turbo oil supply hose for any leakage.

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Image1

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBO OIL SUPPLY HOSE

MODELS INVOLVED - ON CERTAIN C7.1 GENERATOR SETS

Dear Cat Product Owner:

The turbo oil supply hose needs to be replaced on the products listed below. The existing turbo oil supply hose can leak oil. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 27Jan2016 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 27Jan2016 Service Letter