PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBOCHARGER OIL LINES ON TWIN TURBOCHARGER EQUIPPED G3516C, G3516E, G3520C, AND G3520E ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBOCHARGER OIL LINES ON TWIN TURBOCHARGER EQUIPPED G3516C, G3516E, G3520C, AND G3520E ENGINES

Usage:

REBE2276-02

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16Nov2007

(Revised 01Apr2008)

U-592

A-483

D-484

O-519

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBOCHARGER OIL LINES ON TWIN TURBOCHARGER EQUIPPED G3516C, G3516E, G3520C, AND G3520E ENGINES
1307 1052		PI31398

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31398" 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 "PI31398" 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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NOTE:	This Revised Service Letter replaces the 16Nov2007 (Revised 18Dec2007) Service Letter. Changes have been made to the Affected Product and Step 3 of Group Number 1 Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
31May2008	30Nov2008

PROBLEM

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Certain G3516C, G3516E, G3520C, and G3520E engines equipped with twin turbochargers have experienced oil leaks at the turbocharger oil supply lines.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
G3516C	GSB00113 GZZ00114-00173, 180-188 TJB00101-00109 TJC00817-00819
G3516E	GAS00111-00150 SLY00106-00109
G3520C	B9P00101-00104, 200-214 CWY00100-00104, 200-221 GZJ00161-00221 GZK00151-00166 GZM00131-00161 HAT00102, 200-211 MAD00101-00102, 200-201
G3520E	GZG00111 GZH00111-00123 HAL00100-00102 SXY00100-00102

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*****Group 2*****
G3516C	GSB00114-00119 GZZ00189-00242
G3516E	GAS00151-00214
G3520C	GZJ00222-00313 GZK00167-00182 GZL00141-00143 GZM00162-00177, 179

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	0S1594	BOLT
2	1A2029	BOLT
4	3E4352	WASHER-HARD
4	4B3388	BOLT
4	5P3456	SEAL-O-RING
1	6V4589	SEAL-O-RING
4	6V5134	SEAL-O-RING
4	6V8337	BOLT-SOCKET HD
2	7N8229	STRAINER AS
2	7S3916	CLIP
2	7S3919	CLIP
3	7V6571	GROMMET
2	8C0624	SEAL-O-RING
2	8N9885	GASKET-DRIVE HSG
1	8T1889	CLIP-2 PIECE
1	8T1890	CLIP-2 PIECE
1	9M4584	CONNECTOR-FLARED
1	0307972	ELBOW
2	0307983	UNION-FLARED
1	0618284	TEE-SWIVEL
1	1664985	HOSE AS
2	1665022	ELBOW
2	2839571	COVER AS
2	2841210	TUBE
1	3025876	BRACKET
2	3025877	TUBE AS
2	3025878	BRACKET
1	3125614	HOSE AS
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an inital 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*****
1	0S1594	BOLT
2	1A2029	BOLT
4	3E4352	WASHER-HARD
4	5P3456	SEAL-O-RING
1	6V4589	SEAL-O-RING
4	6V8337	BOLT-SOCKET HD
2	7N8229	STRAINER AS
2	7S3916	CLIP
2	7S3919	CLIP
3	7V6571	GROMMET
2	8C0624	SEAL-O-RING
1	8T1889	CLIP-2 PIECE
1	8T1890	CLIP-2 PIECE
1	9M4584	CONNECTOR-FLARED
1	0307972	ELBOW
2	0307983	UNION-FLARED
1	0618284	TEE-SWIVEL
1	1664985	HOSE AS
1	3025876	BRACKET
2	3025877	TUBE AS
2	3025878	BRACKET
1	3125614	HOSE AS
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an inital 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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The rigid turbocharger oil supply lines need to be updated with flexible turbocharger oil supply lines on the affected products. Group 1 engines will also require turbocharger drain lines to be updated. Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 4.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.5-hour job for Group 2

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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE TURBOCHARGER OIL LINES ON TWIN TURBOCHARGER EQUIPPED G3516C, G3516E, G3520C, AND G3520E ENGINES

MODELS INVOLVED - G3516C, G3516E, G3520C, and G3520E Engines

Dear Caterpillar Product Owner:

The turbocharger oil lines need to be replaced on the products listed above. The existing oil lines may leak. 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 16Nov2007 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 16Nov2007 Service Letter

Rework Procedure

Group Number 1

NOTE: Care should be taken to ensure that contamination is not introduced into the turbocharger oil supply system.

NOTE: Lubricate o-rings with light coat of engine oil during installation.

NOTE: Some Nuts, Bolts, and Washers will need to be reused from original turbocharger oil lines group.

Refer to image 1.1.1.

1. Completely remove rigid turbo oil supply lines, clamps, and fittings from engine.

2. Remove turbo oil drain lines from both turbochargers. This includes removing the cover from the front housing, as it will be replaced.

3. Install new 283-9571(1) Cover As. using the 8N-9885 Gasket. If the engine is equipped with an automatic oil leveler, the 283-9571 Cover As. may need drilled and tapped 1/4 - 18 NPTF for the vent line.

4. Install two new 284-1210 Turbocharger Oil Drain lines (2), with 6V-5134 O-rings. The drain line will slide into the turbocharger and the 166-5022(3) Elbow, which attaches to the Cover As with 4B-3388 Bolts and 8C-0624 O-ring.

Image1.1.1

Refer to images 1.2.1 and 1.2.2 for this procedure.

5. Install 030-7983 Union and 061-8284 Tee onto one of the 302-5877 Tube Assemblies (1). Install 030-7893 Union and 030-7972 Elbow onto the other 302-5877 Tube Assembly.

6. Install 302-5877 Tube Assemblies (1) to each turbocharger supply inlet with 3E-4352 Washer, 6V-8337 Bolt, 5P-3456 O-ring, and 7N-8229 Strainer As. The 5P-3456 O-ring needs to be installed in the O-ring groove on the 302-5877 Tube Assembly at the tube assembly to 7N-8229 Strainer connection. The Tube Assembly with the Tee fitting goes on the left side turbocharger.

NOTE: Do not install an O-ring between the strainer and the turbocharger.

7. Install 302-5876 Bracket (2) onto front end of left side water manifold.

8. Install 302-5878 Brackets (3) onto exhaust elbow and secure with previously removed 9X-8873 Bolt, 5P-8245 Washer, and 1F-7958 Nut.

9. Install 9M-4584 Connector with 6V-4589 O-ring onto the oil distribution block.

10. Install the 166-4985 Hose Assembly (4) between distribution block and left side turbocharger supply.

11. Secure 166-4985 Hose Assembly to 302-5876 Bracket with 8T-1889/8T-1890 Clamp and 7V-6571 Grommet. Use 0S-1594 Bolt, 5M-2894 Washer, and 9S-8752 Nut for securing the clamp to the bracket.

12. Install 312-5614 Hose Assembly (5) between left side and right side turbocharger supplies.

13. Secure 312-5614 Hose Assembly with 7S-3916/7S-3919 Clamp and 7V-6571 Grommet to the 302-5878 Bracket on exhaust elbow. Use 1A-2029 Bolt, 5M-2894 Washer, and 9S-8752 Nut for securing the clamp to the bracket.

Image1.2.1

Image1.2.2

14. Run engine at high idle with no load for 5 minutes. Check for leaks.

NOTE: Engine components and oil will be hot. Use caution when performing work.

15. Remove 7N-8229 Strainer Assemblies installed in Step 6. Connect tube assemblies directly to the turbochargers using new 5P-3456 O-rings.

16. Run engine at high idle with no load for 5 minutes. Check for leaks. Rectify as necessary.

Group Number 2

NOTE: Care should be taken to ensure that contamination is not introduced into the turbocharger oil supply system.

NOTE: Some Nuts, Bolts, and Washers will need to be reused from original turbocharger oil lines group.

NOTE: Lubricate o-rings with light coat of engine oil during installation.

Refer to images 1.2.1 and 1.2.2 above for this procedure.

1. Completely remove rigid turbocharger oil supply lines, clamps, and fittings from engine.

2. Install 030-7983 Union and 061-8284 Tee onto one of the 302-5877 Tube Assemblies (1). Install 030-7893 Union and 030-7972 Elbow onto the other 302-5877 Tube Assembly.

3. Install 302-5877 Tube Assemblies (1) to each turbocharger supply inlet with 3E-4352 Washer, 6V-8337 Bolt, 5P-3456 O-ring, and 7N-8229 Strainer As. The 5P-3456 O-ring needs to be installed in the O-ring groove on the 302-5877 Tube Assembly at the tube assembly to 7N-8229 Strainer connection. The Tube Assembly with the Tee fitting goes on the left side turbocharger.

NOTE: Do not install an O-ring between the strainer and the turbocharger.

4. Install 302-5876 Bracket (2) onto front end of left side water manifold.

5. Install 302-5878 Brackets (3) onto exhaust elbow and secure with previousely removed 9X-8873 Bolt, 5P-8245 Washer, and 1F-7958 Nut.

6. Install 9M-4584 Connector with 6V-4589 O-ring onto the oil distribution block.

7. Install the 166-4985 Hose Assembly (4) between distribution block and left side turbo supply.

8. Secure 166-4985 Hose Assembly to 302-5876 Bracket with 8T-1889/8T-1890 Clamp and 7V-6571 Grommet. Use 0S-1594 Bolt, 5M-2894 Washer, and 9S-8752 Nut for securing the clamp to the bracket.

9. Install 312-5614 Hose Assembly (5) between left side and right side turbo supplies.

10. Secure 312-5614 Hose Assembly with 7S-3916/7S-3919 Clamp and 7V-6571 Grommet to the 302-5878 Bracket on exhaust elbow. Use 1A-2029 Bolt, 5M-2894 Washer, and 9S-8752 Nut for securing the clamp to the bracket.

11. Run engine at high idle with no load for 5 minutes. Check for leaks.

NOTE: Engine components and oil will be hot. Use caution when performing work.

12. Remove 7N-8229 Strainer Assemblies installed in Step 3. Connect tube assemblies directly to the turbochargers using new 5P-3456 O-rings.

13. Run engine at high idle with no load for 5 minutes. Check for leaks. Rectify as necessary.