THE HYDRAX OIL LINES, TUBES AND SUPPORT CLIPS NEED TO BE CHANGED TO ELIMINATE SUPPORT CLIP FAILURES ON CERTAIN G3606 AND G3608 GAS ENGINES Caterpillar

THE HYDRAX OIL LINES, TUBES AND SUPPORT CLIPS NEED TO BE CHANGED TO ELIMINATE SUPPORT CLIP FAILURES ON CERTAIN G3606 AND G3608 GAS ENGINES

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Caterpillar: Confidential Yellow

THE HYDRAX OIL LINES, TUBES AND SUPPORT CLIPS NEED TO BE CHANGED TO ELIMINATE SUPPORT CLIP FAILURES ON CERTAIN G3606 AND G3608 GAS ENGINES SEBE7359-03

June 30, 2000

(Revised January 2001)
U-200
A-149

AU-118
S-90

H-64
O-176

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Safety	THE HYDRAX OIL LINES, TUBES AND SUPPORT CLIPS NEED TO BE CHANGED TO ELIMINATE SUPPORT CLIP FAILURES ON CERTAIN G3606 AND G3608 GAS ENGINES
0709		PI10021

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10021" 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 "PI10021" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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.

NOTE: This Revised Service Letter replaces the June 30, 2000 (Revised September 2000) Service Letter. Changes have been made to the Affected Product.

PROBLEM

The hydrax oil lines, tubes and support clips need to be changed to eliminate support clip failures on certain G3606 and G3608 Gas Engines. The more robust support clips and bracket will properly secure the oil lines, thus eliminating wear and fatigue failure of the lower oil lines that run along the rear of the engine. If the oil lines fail, high-pressure hydraulic fluid could be released.

AFFECTED PRODUCT

G3606 3XF17-251

G3608 4WF16-159

NOTE: The effective product serial number range for the Hydrax system are 3XF211 and 4WF68. It will be necessary to determine if engines prior to these serial numbers have been field converted to the Hydrax system. If so, update those engines per this service letter. If not, submit a SIMS report stating that the engine does not have the Hydrax system installed.

PARTS NEEDED

2 - 7C8246 Spacer
2 - 0S1594 Bolt
2 - 9S8752 Nut - Full
2 - 8T1885 Clip
2 - 8T1886 Clip
2 - 8T1887 Clip
2 - 8T1888 Clip
4 - 3V3308 Washer - Hard
1 - 1763591 Bracket Assembly
1 - 1845287 Tube Assembly
1 - 1845288 Tube Assembly

ACTION REQUIRED

See the attached procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	2	0	0	0	0
NOTE: This is a 2-hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

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.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - The Hydrax Oil Lines, Tubes and Support Clips Need To Be Changed To Eliminate Support Clip Failures

MODELS INVOLVED - G3606 and G3608 Gas Engines

Dear Caterpillar Product Owner:

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated June 30, 2000 when scheduling this service. You will not be charged for the service performed.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to June 30, 2000 Service Letter

Rework Procedure

NOTE: For G3606 engines configured with the 1726405 Turbo Group(TPS57D), the wastegate hydraulic actuator oil supply and return lines are routed to a different location and will not be replaced per this program. The support bracket, tube mounting hardware for location Y1 and Y2 and the 1845287 Tube Assemblies are the main parts required for updating a TPS57D turbocharger configuration. Refer to the TPS57D graphic at the end of this section. Engines equipped with the VTC254 turbocharger configuration will use all the hardware listed for this program.

1. Remove 1B3057 Clips, 5K9660 Clips, 1V6256 Spacers, 1317748 Bracket As., 1319378 Tube As., 1419903 Tube As. (G3606 and G3608 VTC254 turbo configurations only.)

2. Loosely install 1845287 Tube As. and 1845288 Tubes As. (not required for G3606 TPS57D turbo configuration).

Loosely install 1763591 Bracket Assembly using previous bracket mounting hardware.
For the G3606 and G3608 engine configured with VTC254 Turbocharger, refer to the VTC254 Turbo Configuration graphic then complete the following installation procedure:

Loosely install the 8T1885 Clips, 8T1886 Clips, 7C8246 spacer, and previous mounting hardware to the upper left(X1) and lower right(X2) hole positions of the 1763591 Bracket Assembly.
Loosely install 8T1887 Clips, 8T1888 Clips, 0S1594 bolts, 3V3308 Washers, 9S8752 Nuts to the upper right (Y1) and lower left (Y2) bolt hole locations of the 176 bracket assembly.

5. For the G3606 engines configured with the TPS57D Turbo Configuration, refer to the TPS57D Turbo configuration graphic. Then loosely install 8T1887 Clips, 8T1888 Clips, 0S1594 bolts, 3V3308 Washers, and 9S8752 Nuts to the upper right(Y1) and lower left(Y2) bolt hole locations of the 1763591 bracket assembly.

After all hardware is loosely installed, begin tightening mounting hardware, ensuring that binding or side loading of the tube assemblies does not occur.