PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TURBOCHARGER COOLANT LINES ON CERTAIN G3516B ULTRA LEAN BURN (ULB) ENGINES Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TURBOCHARGER COOLANT LINES ON CERTAIN G3516B ULTRA LEAN BURN (ULB) ENGINES

Usage:

REBE5995-01

13Apr2010
(Revised 07May2010)


U-122

 
Safety
  
  

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TURBOCHARGER COOLANT LINES ON CERTAIN G3516B ULTRA LEAN BURN (ULB) ENGINES

1393 1355 1380
PI10797
NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10797" 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 "PI10797" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

 
NOTE:

This Revised Service Letter replaces the 23Mar2010 Service Letter. Changes have been made to Service Claim Allowance.



PROBLEM

The 335-3958 and 330-4018 turbocharger coolant lines can crack, creating a coolant leak at the turbo charger connection on certain G3516B ULB engines. Failure of these lines can cause a fire and may create a risk of personal injury or death.

AFFECTED PRODUCT

Model Identification Number
G3516B  JEF00108-00136

PARTS NEEDED

Qty

Part Number Description
1 0S1588 BOLT
1 0S1594 BOLT
3 5G3676 GROMMET
8 5M2894 WASHER-HARD
1 5P8245 WASHER-HARD
1 6D4246 CLIP-LOOP
2 6V5064 SEAL-O-RING
2 6V8556 NUT-ORFS
1 6V8733 ADAPTER-STR
2 6V8942 REDUCER-O-RING
2 7S3916 CLIP
2 7S3919 CLIP
4 8C4424 PLUG-STOR
1 8F8804 BOLT
2 8T1685 TEE-SPL
4 8T7492 ADAPTER-STR
2 9S8752 NUT-FULL
2 9X6458 WASHER-HARD
1 1271958 SPACER
4 1808424 SEAL-O-RING
8 2167485 SEAL-O-RING-STOR
10 2502343 SEAL-O-RING
1 3304021 HOSE AS
1 3418714 HOSE AS
1 3418715 HOSE AS
1 3418716 HOSE AS
1 3418717 HOSE AS
1 3418718 TUBE AS
2 3418719 BRACKET
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

Replace the existing 328-2645 turbocharger coolant lines group with the braided 341-8736 turbocharger coolant lines.

Refer to the attached rework procedure.

OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 7.0-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.
 
 
 
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING TURBOCHARGER COOLANT LINES

MODELS INVOLVED - G3516B

Dear Caterpillar Product Owner:

The turbocharger coolant lines need to be replaced on the products listed below. The existing turbocharger coolant lines can crack and leak. Failure of these lines can cause a fire and may create a risk of personal injury or death. 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 13Apr2010 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 13Apr2010 Service Letter


Rework Procedure


 
Refer to Image1.1.1 for the parts list.
Refer to the Top, Rear, Left, and Sectional views for parts callout details.

- Shutdown the engine and allow to cool.

- Drain the coolant.
Image1.1.1
 
Refer to Image1.2.1

1. Remove the 330-4018 Tube Assembly. Install the 341-8715 Hose Assembly (8) and 180-8424 O-Ring seal (3).

2. Remove the 335-3958 Tube Assembly. Install the 341-8714 Hose assembly (7), 180-8424 O-Ring Seals (3), 6V-8556 Nut Orifice (17), and 6V-8942 Reducer-O-Ring (19).

3. Remove the 335-3959 Hose Assembly. Install the 330-4021 Hose Assembly (6).
Image1.2.1
 
Refer to Image1.3.1

4. Install the 341-8717 Hose Assembly (10).

5. Install the 5G-3676 Grommet (13), 7S-3916 Clip (20), 7S-3919 Clip (21), 127-1958 Spacer (29), 5P-8245 Washer (28), and the 8F-8804 Bolt (27).

6. Remove the 335-3957 Hose Assembly. Install the 341-8716 Hose Assembly (9)and associated parts. Refer to Step 8 and Step 9, and sectional view C-C shown in Image1.4.1 for further details.

7. Install the 341-8719 Bracket (12), 341-8718 Tube Assembly (11), and the associated parts. Refer to Step 10 and Step 11, and sectional view B-B shown in Image1.3.1 for further details.
Image1.3.1
 
Refer to Image1.4.1

8. Install the 5G-3676 Grommet (13), 7S-3916 Clip (20), 7S-3919 Clip (21), 341-8719 Bracket (12), 0S-1588 Bolt (1), 9S-8752 Washers(25), and 9X-6458 Washers (26).

9. Install the 216-7485 (4) and 250-2343 (5) O-Ring-Seals and the 8T-7492 Connector(24).
Image1.4.1
 
Refer to Image1.5.1

10. Install the 250-2343 O-Ring-Seals (5) and the 6V-8733 Union-Face Seal (18). Install the 6D-4246 Clip (15), 216-7485 (4) and 250-2343 (5) O-Ring-Seals, and the 8T-7492 Connector (24) .

11. Use the 0S-1594 Bolt (2), 5M-2894 Washer( 14), and 9S-8752 Nut (25) for the installation of the bracket.

12. Install the 8C-4424 Plug (22) and 216-7485 O-Ring-Seal (4).
Image1.5.1
 
Refer to Image1.6.1

13. Install the 8T-1685 Tee-Special (23), 6V-5064 O-Ring-Seals (16), and the 250-2343 O-Ring-Seal (5).
Image1.6.1
 
14. Add coolant and check for leaks.

15. Start engine and check for leaks.

16. Load engine and check for leaks.
 
 

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