PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING THE CRANKCASE BREATHER OIL DRAIN LINES ON CERTAIN C32 MARINE GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING THE CRANKCASE BREATHER OIL DRAIN LINES ON CERTAIN C32 MARINE GENERATOR SETS

Usage:

REBE8901-00

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08Oct2012

U-526

A-418

D-450

O-484

TM-6

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING THE CRANKCASE BREATHER OIL DRAIN LINES ON CERTAIN C32 MARINE GENERATOR SETS
1074 1307 1317		PI32103

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32103" 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 "PI32103" 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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COMPLETION DATE	TERMINATION DATE
30Apr2013	31Oct2013

PROBLEM

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The crankcase breather oil drain lines need to be installed on certain C32 Marine Generator Sets. The oil drain lines were not installed in the factory. The crankcase filters can leak if these lines are not installed.

AFFECTED PRODUCT

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Model	Identification Number
C32	RNF00156-00164, 167-170

PARTS NEEDED

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Qty	Part Number	Description
2	0S1588	BOLT
2	4L6454	BOLT
2	4N1199	CLIP
2	5M2894	WASHER-HARD
179	5P1505	HOSE-BULK (179 cm)
2	6D4246	CLIP-LOOP
2	6V8801	NUT
1	8C6427	ADAPTER
4	8T4896	WASHER-HARD
6	1091145	CLAMP-HOSE
1	2877250	ADAPTER-TEE
1	3489705	VALVE AS-CHECK
1	3544821	TUBE 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 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

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Do not perform any procedure in this Service Letter until you have read this information and you understand this information.

Make sure the work area around the product is made safe and be aware of hazardous conditions that may exist.

When you service a marine generator set or when you repair a marine generator set, follow the following shutdown procedure:

1. Disconnect the generator from the distribution system by opening the generator circuit breaker.

2. Lock out the circuit breaker. Attach a "DO NOT OPERATE" or similar warning tag to the circuit breaker. Refer to the electrical diagram. Verify that all points of possible reverse power flow have been locked out.

3. Stop the engine, after cool-down cycle.

4. Attach a "DO NOT OPERATE" or similar warning tag to the engine prime mover starting circuit.

5. Disconnect the engine starting circuit.

6. For the following circuitry, remove the transformer's fuses or open circuit breakers:
power
sensing
control

7. Remove the cover of the generator's terminal box.

8. Use an audio/visual proximity tester in order to verify that the generator is de-energized. This tester must be insulated for the proper voltage rating. Follow all guidelines in order to verify that the tester is operational.

9. Determine that the generator is in a de-energized condition. Add ground straps to the conductors or terminals. During the entire work period, these ground straps must remain connected to the conductors and to the terminals.

Refer to the following Rework Procedure:

Note: Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced.

1. Cut the hose to required lengths: 15cm, 38cm, and 126cm.

2. Remove the 8T-6765 Pipe Plug from the front 303-8487 Inspection Cover on left hand side of engine as shown in Image1. The plug will not be reused.

3. Assemble the 8C-6427 Adapter to the cover and tighten to 35Nm.

4. Assemble the 348-9705 Check Valve Assembly to the adapter and tighten to 35Nm. Ensure that it is oriented as shown in Image1.

5. Assemble the 354-4821 Tube Assembly to the check valve and tighten the nut to 55Nm. Ensure that it is oriented as shown in Image1.

6. Remove the 0S-1594 Bolt and 5M-2894 Washer from rear 303-8487 Inspection Cover on the left hand side of engine as shown in Image1. The bolt and washer will not be reused.

7. Assemble the 4N-1199 Clip to the cover with a 0S-1588 Bolt and 5M-2894 Washer, and tighten to 47Nm. Ensure that the clip is oriented as shown in Image1.

8. Remove the 0S-1594 Bolt and 5M-2894 Washer from the 247-6393 Cover Group on the rear of the engine as shown in Image2. The bolt and washer will not be reused.

9. Assemble the 4N-1199 Clip to the cover with a 0S-1588 Bolt and 5M-2894 Washer, and tighten to 47Nm. Ensure that the clip is oriented to the 11 O'clock position, as shown in Image2.

10. Secure the 15cm length of hose to the bottom of the left hand mounted filter assembly using a 109-1145 Hose Clamp. Secure the 38cm length of hose to the bottom of the right hand mounted filter assembly using a 109-1145 Hose Clamp. Refer to Image3. Use P-80 lubricant to assist in assembly. Tighten the clamps to 4.5Nm.

11. Secure both hoses to the 287-7250 Tee Adapter using 109-1145 Hose Clamps, as shown in Image3. Use P-80 lubricant to assist in assembly. Tighten the clamps to 4.5Nm.

12. Secure the 126cm length of hose to 287-7250 Tee Adapter and 354-4821 Tube As using 109-1145 Hose Clamps, as shown in Image3. Use P-80 lubricant to assist in assembly. Tighten the clamps to 4.5Nm.

13. Install two 6D-4246 Loop Clips on the 126cm length of hose. Secure the loop clips to the previously assembled 4N-1199 Clips using 4L-6454 Bolts, 8T-5896 Washers-Hard, and 6V-8801 Nuts, as shown in Image4. Tighten to 47Nm.

14. Paint the adapter, check valve, tube, and clips.

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Image1

Image2

Image3

Image4

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%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.0-hour job
There is a $30 miscellaneous allowance for purchase of paint to match the engine. There is a $20 miscellaneous allowance for purchase of P-80 Assembly Lubricant to ease assembly of the hoses.

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PARTS DISPOSITION

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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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING THE CRANKCASE BREATHER OIL DRAIN LINES ON CERTAIN C32 MARINE GENSET ENGINES

MODELS INVOLVED - C32

Dear Caterpillar Product Owner:

The crankcase breather oil drain lines need to be installed on the products listed below. The crankcase filters can leak if these lines are not installed. 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 08Oct2012 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 08Oct2012 Service Letter