PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE HYDRAX SUPPLY TUBES ON CERTAIN G3606 AND G3608 ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE HYDRAX SUPPLY TUBES ON CERTAIN G3606 AND G3608 ENGINES

Usage:

SEBE8314

March 10, 2003
U-66

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE HYDRAX SUPPLY TUBES ON CERTAIN G3606 AND G3608 ENGINES
1307		PI10217

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10217" 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 "PI10217" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

PROBLEM

The hydrax supply tubes need to be replaced on certain G3606 and G3608. The first G3606 and G3608 inline engine with the ADEM III control system experienced breakage of the hydrax supply tubes at early hours, which could result in a burn and/or a fire hazard.

AFFECTED PRODUCT

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Model	Identification Number
3606	4ZS281-302
3608	BEN208-217

PARTS NEEDED

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Qty	Part Number	Description
1	9C5344	SPACER
1	0S1591	BOLT
1	9S8752	NUT-FULL
3	8T1887	CLIP
3	8T1888	CLIP
2	3V3308	WASHER-HARD
1	1253902	TUBE AS
1	1319372	TUBE AS

ACTION REQUIRED

If the engine is in service replace the 1319372 Tube As. and the 1253902 Tube As.
Install 2 8T1887 and 2 8T1888 Clips on the lines using a 0S1591 Bolt and a 9C5344 Spacer, 2 3V3308 washers, and a 9S8752 Nut.
Also install an 8T1887 and 8T1888 Clip in place of the current clip on the rear crankcase cover.
If the engine has less than 20 hours replace the clips only.

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%	1.0	0	0	0	0
NOTE: This is a 1.0-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 - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE HYDRAX SUPPLY TUBES

MODELS INVOLVED - CERTAIN G3606 AND G3608 ENGINES

Dear Caterpillar Product Owner:

New hydrax lines need to be installed on the products listed below. The first G3606 and G3608 inline engine with the ADEM III Control System experienced breakage of the hydrax supply tubes at early hours, which could result in a burn and/or a fire hazard. The tubes may need to be replaced, and clips will be added to the tubes. You will not be charged for the service performed.

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 March 10, 2003 when scheduling this service.

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 March 10, 2003 Service Letter

Rework Procedure

NOTE: If the engine has 20 or more hours on the service meter (MIDS or ET) the 1319372 Tube As. and 1253902 Tube As. must be replaced. If the engine has less than 20 hrs. on the service meter then only the 3 clip Assemblies need to be added.

Place a container at the lowest point under the Hydrax check valve and loosen the tubing nuts on the 1319372 Tubes As. and the 1253902 Tube As.
After the hydraulic fluid has drained remove the old 1319372 and 1253902 Tube Assemblies and replace with new tubes.
Remove the 5K9660 Clip that secures the 1319376 Tube As. to the rear crankcase cover.
Replace the 5K9660 Clip with an 8T1887 and 8T1888 Clip. The same bolt, spacer, and washer may be reused.
Torque bolt to 47 Nm+/-5Nm.
Next, position one 8T1887 and one 8T1888 on the 1319372 Tube As approximately 2 inches forward of the 90⁰ bend.
Place another 8T1887 and 8T1888 Clip on the 1319376 Tube As. at 90⁰ to the previously installed clip and approximately 2 inches above the bend in the tube.
Tie the two tubes together using the 2 clip assemblies previously installed and, one 0S1591 Bolt, two 3V3308 Washers, one 9C5344 spacer, and one 9S8752 Nut.
Torque the bolt to 47Nm +/-5 Nm.
Refill the hydraulic reservoir as needed.
Run engine and check for leaks.