PRODUCT SUPPORT PROGRAM FOR UPDATING THE OIL MIST DETECTOR ON MARINE AND PETROLEUM 3612 AND C280-12 ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE OIL MIST DETECTOR ON MARINE AND PETROLEUM 3612 AND C280-12 ENGINES

Usage:

REBE8370-01

Show/hide table

29Oct2012

(Revised 05Aug2013)

U-569

A-449

D-487

O-525

Show/hide table

*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE OIL MIST DETECTOR ON MARINE AND PETROLEUM 3612 AND C280-12 ENGINES
1336		PS43739

Show/hide table

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43739" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 29Oct2012 Service Letter. Changes have been made to the Service Claim Allowances.

Show/hide table

TERMINATION DATE

31Oct2014

PROBLEM

Show/hide table

The existing 193-0659 Oil Mist Detector (OMD) group is susceptible to frequent false positive shutdowns causing the engine to shutdown without warning.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
3612	9RC00328-00329, 357, 360-367, 371-372, 378-383, 386-393, 402-409, 411, 413-414, 416-423, 449-450, 455, 457-461, 465-467, 472, 476, 478-480, 483-484
C280-12	RDW00103-00104, 109-112, 117, 120, 131-132, 135-138, 141-146, 151-155 TSJ00100-00103, 108-111, 113-114, 126-127, 141-146, 150-151, 153-160

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
2	0S1591	BOLT
6	0S1594	BOLT
4	1A2029	BOLT
2	1B7182	BOLT
4	1S1409	CLIP
4	2B2695	BOLT
8	3E4352	WASHER-HARD
8	3V3308	WASHER-HARD
4	5C7261	NUT-HEX
2	5S0003	NUT-FULL
6	6I4545	SEAL-O RING
1	6M6853	TEE-O-RING RUN
7	6V0408	SEAL-BONDED
5	6V1904	SEAL-O RING
2	6V3527	FITTING-FLARED
4	6V3918	BOLT-HEX HEAD
6	9M1974	WASHER-HARD
4	9S8752	NUT-FULL
2	0019440	ADAPTER-STR
3	0307942	ADAPTER-ELBOW
1	0307947	ADAPTER-ELBOW
2	0307950	ADAPTER-ELBOW
6	1921405	NUT
6	1921406	FERRULE
5	2147568	SEAL-O-RING-STOR
2	2385082	SEAL-O-RING-STOR
1	2675286	FILTER AS
1	3685085	HOSE AS
3	3685086	PIPE-OIL SIPHON
1	3717602	BRACKET AS
1	3717603	BRACKET AS
1	3717604	HOSE AS
1	3725027	HOSE AS
1	3898632	TUBE AS
1	3913031	MANIFOLD AS
1	3913032	MANIFOLD AS
1	3945609	HOSE AS
1	3945610	HOSE AS
1	3945612	HOSE AS
1	3966581	TUBE AS
4	3975346	BRACKET
2	3977660	HOSE AS
1	4165548	HOSE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 28% 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

Show/hide table

Four engine side covers per engine require rework for use with the updated oil mist detection system. A limited number of spare covers are available upon request and will be exchanged with the side covers removed during the upgrade. Contact Customer Service for more information. For Marine Engines, contact Steve Hoffman at 765-448-2452 or Hoffman_Steve_W@cat.com. For Petroleum Engines, contact Brad Devorak at 765-448-5046 or Devorak_Brad_C@cat.com.

Refer to Hydraulic Information System (HIS) to build the hose assemblies that are listed in the Parts Needed.

Refer to the attached Rework Procedure.

Show/hide table

Image1

SERVICE CLAIM ALLOWANCES

Show/hide table

Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-200000 hrs, 0-168 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

Show/hide table

NOTE: This is a 10.0-hour job
A maximum of $300.00 U.S. will be allowed for machining rework of the engine side covers. Include outside expenses at cost. Retain a copy of all invoices for outside expenses in the engine history folder for audit purposes.

Show/hide table

PARTS DISPOSITION

Show/hide table

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

Show/hide table

- Ensure that four engine side covers per engine being updated are reworked prior to starting this rework procedure to the oil mist detector system.

Reference the 394-5196 Oil Mist Detector Group and the 394-9775 (LH) or 394-9776 (RH) Air Lines Group.

- Perform all steps necessary to prepare the engine for safely installing the new oil mist detector (OMD) system.

- 1) Remove the current exhaust hose from the outlet of the OMD. The hose will not be reused but keep the hardware for reuse.

- 2) Remove the 2 hoses connected between the manifolds and the OMD. The hoses will not be reused but keep all hardware between the hoses and OMD because they will be reused.

- 3) Carefully disconnect the hose and tube from the 144-0526 Pressure Regulator (both will be reused) and disconnect the tube from the other pressure regulator (this regulator will not be reused).

Image1.2.1

- 4) Remove and discard the hose connected between the supply air tube and 144-0526 Pressure Regulator.

- 5) Remove the pressure regulators from the OMD support bracket (dispose of the larger pressure regulator but keep the smaller 144-0526 Pressure Regulator for reuse). Inspect 144-0526 Pressure Regulator for corrosion and replace as needed.

- 6) Remove the oil collection box and discard.

Image1.3.1

Image1.3.2

- 7) Remove the bolts supporting the manifolds.

- 8) Loosen the 192-1405 Nut on each of the suction tubes and carefully remove and discard both manifolds. The 192-1406 Ferrules will not be able to be removed and will not be reused along with the nut and manifolds.

Image1.4.1

Image1.4.2

- 9) Carefully remove the explosion relief valves from these four covers and set aside for reuse. Remove all six covers from this side of the engine to gain access to the suction funnels located in each compartment of the crankcase.

Image1.5.1

Image1.5.2

- 10) Carefully loosen the connections between the suction funnels and the block. Rotate each as shown in Image 1.6.2 with the opening of the suction funnel at either the 4 O'clock position or the 8 O'clock position. The suction funnel openings will be pointed away from the main bearing webs. Tighten to 35 +/- 5 N.m.

Image1.6.1

Image1.6.2

- 11) Install the reworked explosion relief valve covers in the four locations shown in Image 1.7.1 with the machined port positioned in the lower left as shown in Image 1.7.2. Install the explosion relief valves removed earlier. Replace the two bolts that mounted the oil collection box with two 0S-1591 Bolts. Reinstall the remaining two crankcase covers that were removed earlier.

Image1.7.1

Image1.7.2

- 12) Using 371-7602 Bracket and 371-7603 Bracket, mount the 144-0526 Regulator. Note new orientation of regulator. See Image 1.8.1 for hardware.

- 13) Install the 267-5286 Air Filter, 371-7604 Hose (RH mounted), 372-5027 Hose (LH mounted), and 396-6581 Tube. See Image 1.8.2 for hardware.

Image1.8.1

Image1.8.2

Image1.8.3

- 14) Install the 391-3032 Right Manifold and 391-3031 Left Manifold using six 192-1406 Ferrules and 192-1405 Nuts.

- 15) Install the new 397-5346 Manifold Support Brackets, see Image 1.9.1 for hardware.

- 16) Install new 030-7950 Fittings, 238-5082 Seals, and 397-7660 Hoses between the manifolds and OMD head using the parts set aside for reuse earlier.

- 17) Install new fitting in the explosion relief port and hose between the exhaust of the OMD head and the new fitting.

Image1.9.1

- 18) Mount engine wall connections into the 3/4 inch side cover ports and tighten to 110 N.m.

- 19) Mount the pipe siphon into the wall connection.

- 20) Fill the siphon with 70 mL of engine oil.

- Caution, overfilling siphon can cause a draining affect causing improper operation.