PRODUCT IMPROVEMENT PROGRAM FOR REROUTING THE TURBO OIL SUPPLY LINE ON CERTAIN C-10, C-12, AND 3176C ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REROUTING THE TURBO OIL SUPPLY LINE ON CERTAIN C-10, C-12, AND 3176C ENGINES

Usage:

SEBE8461-04

August 8, 2003
(Revised March 2004)
U-208
A-147
D-152
O-170
TT-18

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REROUTING THE TURBO OIL SUPPLY LINE ON CERTAIN C-10, C-12, AND 3176C ENGINES
1052		PI30517

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30517" 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 "PI30517" 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 August 8, 2003 (Revised February 2004) Service Letter. Changes have been made to add a note to the Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
February 28, 2004	August 31, 2004

PROBLEM

The turbo oil supply line needs to be rerouted on certain C-10, C-12, and 3176C engines. The turbocharger oil supply line may be misrouted on some units, making it possible for the line to rub against the turbo housing. This may cause the turbocharger line to fail.

AFFECTED PRODUCT

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Model	Identification Number
C-10	3CS28286-29212 8YS7761-7766
C-12	2KS77516, 77774, 77859, 77905, 78097, 78098, 78310, 78452, 48453, 79277, 79319, 79320, 79411, 79412, 79909, 80043, 80478, 80510, 80570, 80808, 81126, 81440, 81610, 81767, 81941, 81996, 82004, 82073, 82144, 82148, 82155, 82166, 82187, 82330, 82717, 82736, 82744, 82795, 82796, 82850, 82888, 82898, 82901, 82903, 82905, 82906, 82910, 82911, 82914, 82916, 82923, 82935, 82938, 82983, 83018, 83478, 84120, 84184, 84239, 85822, 86431, 86432, 86433, 86434, 86435, 86436, 86437, 86438, 86439, 86440, 86441, 86442, 86443, 86497, 86564, 86565, 86634, 86635, 86636, 86637, 86672, 86699, 86796, 86797, 86934, 86939, 87030, 87361, 87383, 87384, 87481, 87748, 87934, 87936, 88088, 88089, 88108, 88148, 88149, 88184, 88185, 88187, 88188, 88197, 88198, 88199, 88205, 88206, 88208, 88209, 88210, 88211, 88221, 88349, 88551, 88553, 88807, 88917, 89051, 89052, 89058, 89059, 89060, 89061, 89066, 89075, 89076, 89077, 89078, 89079, 89110, 89137, 89138, 89144, 89146, 89148, 89152, 89155, 89181, 89182, 89183, 89184, 89186, 89190, 89191, 89192, 89202, 89225, 89233, 89237, 89248, 89251, 89252, 89255, 89264, 89267, 89287, 89288, 89319, 89320, 89321, 89322, 89323, 89324, 89345, 89383, 89441, 89445, 89447, 89450, 89480, 89502, 89517, 89699, 89702, 89703, 89827, 89828, 89829, 89830, 89931, 89950, 90045, 90046, 90047, 90048, 90059, 90094, 90218, 90327, 90603, 90655, 90656, 90670, 90691, 90747, 90748, 90749, 90750, 90751, 90752, 90788, 90789, 90866, 90897, 90932, 90933, 91089, 91643, 91676, 91773, 91774, 91787, 91865, 91886, 91887, 91888, 91903, 91908, 91910-96478 CPD661-1135 MBL100-666, 1000-3632 BDL1292-2092 9NS12169, 20520, 20521, 20522, 20523
3176C	2AW1360-1651

PARTS NEEDED

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Qty	Part Number	Description
1	4B0418	CLIP-LOOP
1	5C7261	NUT
1	8L2786	SEAL-O-RING
4	8T4224	WASHER-HARD
1	6V8639	CONNECTOR
2	7X2537	BOLT
1	0336033	SEAL-O RING
1	1978418	GASKET
1	2336594	HOSE AS
1	2336595	HOSE AS

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Engine Arrangement Complete	Hose Required
2294765, 2301689, 2301693, 2301696, 2301704, 2301821, 2301851, 2301920, 2308406, 2308509, 2308602, 2308681, 2308689, 2308690, 2315468, 2315471, 2315556, 2315608, 2315693, 2315704, 2315765, 2315772, 2315780, 2325390, 2325417, 2325422, 2325432, 2325530, 2325556, 2325558, 2325769, 2325781, 2339062, 2339077, 2339087, 2348247, 2348320, 2348358, 2348408, 2348431, 2348501, 2348515, 2348558, 2348560, 2359107, 2359108, 2359110, 2359120, 2359178, 2359180, 2359203, 2359210, 2359218, 2359329, 2359346, 2359355, 2359362, 2359364, 2359436, 2359453, 2359495, 2371525	2336595
All other arrangements	2336594

ACTION REQUIRED

See the attached Rework 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%	1.8	0	0	0	0
NOTE: This is a 1.4-hour job with an additional 0.4 hr allowed for Inspect and Reposition. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report.

LABOR

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SMCS Code	Name	Time Allowed
1052-000-LI	Replace Turbo Line	1.4 hrs
1052-018-LI	Inspect & Reposition	0.4 hrs

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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REROUTING THE TURBO OIL SUPPLY LINE

MODELS INVOLVED - CERTAIN C-10, C-12, AND 3176C ENGINES

Dear Caterpillar Product Owner:

The turbocharger oil supply line may be misrouted on some units, making it possible for the line to rub against the turbo housing. This may cause the turbocharger oil supply line to fail. The turbocharger oil supply line needs to be inspected and rerouted if necessary. 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 August 8, 2003 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 August 8, 2003 Service Letter

Rework Procedure

NOTE: If EITHER the VIN number OR the engine serial number of the unit being repaired matches
those listed on the customer letter, repair the unit, and file the claim.

Check the amount of clearance between 1978353 hose, and turbo hot housing at the closest point.
Check 1978353 hose for signs of rubbing against hot housing, and/or abrasion. Also check for any signs of excessive heat through metal discoloration in the localized area close to the turbo.

If hose shows no signs of rubbing, abrasion or heat damage, proceed to Section 1.
If hose shows signs of rubbing or abrasion, order new hose and proceed to Section 2.

Illustration 1

Section 1

If hose shows no signs of rubbing, abrasion or heat damage, take the following actions:

Loosen fitting between 1978353 Hose (A) and 6V8639 Connector (B).
Remove old clip.

Assemble new 4B0418 (C) Clip to turbo supply line and attach to proper stud on oil filter base with 2 8T4224 Washers and 5C7261 Nut. (1 washer on each side of clip). Do not tighten yet.
Torque down the following 2 connections in this order:

Tighten hose end at the block Connector (B). Make sure to use 2 wrenches when attaching hose to connector in order to minimize twisting of the line. See figure one above.
After Adjusting the slack in the Hose (A) to make sure it is not touching the turbo, tighten the 4B0418 Clip (C) retaining nut to a torque of 28 +/- 7 Nm (21 +/- 5 lb ft).

Verify there is 7-10mm of clearance between Hose (A) and turbo hot housing.

For reference, the threaded end of a 3/8" bolt is approximately 10mm and can be used as a guide.

NOTE: If you cannot achieve 7-10 mm of clearance, go to Section 2, and replace the hose.

Section 2

NOTE: The vast majority of the units covered will require a 2336594 hose, but there are some instances in which a 2336595 is required. Reference the chart above to determine which hose you need.

Remove old supply line from engine.
Confirm connector to block is a 6V8639 Connector (B).

If not, remove old connector, and attach 6V8639 Connector to block with 8L2786 Seal, and apply full torque of 55 +/- 5 Nm (41 +/- 3 lb ft).

Attach supply Hose (A) to 6V8639 Connector (B). Do not tighten yet.
Assemble new turbo oil supply tube connector with 7X2537 bolts, 8T4224 washers, and 1978418 gasket. Do not tighten yet.
Assemble 4B0418 Clip (C) to Turbo Supply Line (A) and attach to proper stud on oil filter base with 2 8T4224 washers and 5C7261 Nut. (1 washer on each side of clip). Do not tighten yet.
Torque down the above 3 connections in the following order.

Tighten two 7X2537 Bolts at the turbo to a torque of 28 +/- 7 Nm (21 +/- 2 lb ft).
Tighten hose end at the block connector. Make sure to use 2 wrenches when attaching hose to connector in order to minimize twisting of the line. See figure one above.
After adujusting the slack in the Hose (A) to make sure it is not touching the turbo, tighten the retaining nut on the 4B0418 Clip (C) to a torque of 28 +/- 7 Nm (21 +/- 5 lb ft).