PRODUCT SUPPORT PROGRAM FOR UPDATING THE OIL MIST DETECTOR ON CERTAIN 3608 AND C280-8 MARINE AND PETROLEUM 3608 AND C280-8 ENGINES ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE OIL MIST DETECTOR ON CERTAIN 3608 AND C280-8 MARINE AND PETROLEUM 3608 AND C280-8 ENGINES ENGINES

Usage:

REBE9076-01

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03Dec2012

(Revised 05Aug2013)

U-642

A-508

D-547

O-589

TM-8

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE OIL MIST DETECTOR ON CERTAIN 3608 AND C280-8 MARINE AND PETROLEUM 3608 AND C280-8 ENGINES ENGINES
1336		PS43775

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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 "PS43775" 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.

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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 03Dec2012 Service Letter. Changes have been made to the Affected Product, Parts Needed, and Service Claim Allowances.

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TERMINATION DATE

31Dec2014

PROBLEM

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The existing 193-0658 Oil Mist Detector (OMD) group is susceptible to frequent false positive shutdowns causing the engine to shutdown without warning.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3608	6MC00665-00666, 692-693, 698, 709, 718, 743-745, 766, 791
C280-8	NDT00108-00109, 112, 114, 116, 118, 120, 122, 124-125, 128-129, 132, 134, 136-137, 139, 142, 144 PKA00106, 108, 111, 113, 115, 117, 119, 121, 123-124, 126, 128-129, 131, 133, 135, 137, 140-141, 143, 148

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*****Group 2*****
3608	6MC00691, 694, 697, 715, 719, 746
C280-8	NDT00103, 105-107, 110-111, 113, 115, 117, 119, 121, 123, 126-127, 130-131, 133, 135, 138, 140-141, 143 PKA00107, 109-110, 112, 114, 116, 118, 120, 122, 125, 127, 130, 132, 134, 136, 138-139, 142, 144-147

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*****Group 3*****
C280-8	NDT00148 PKA00150, 155, 160, 166, 168, 170, 172-173, 176-178

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*****Group 4*****
C280-8	NDT00145-00147 PKA00149, 151-154, 156-159, 162-165, 167, 169

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
6	0L1143	BOLT
2	0S1591	BOLT
6	0S1594	BOLT
2	1B7182	BOLT
4	2B2695	BOLT
10	3V3308	WASHER-HARD
4	5C7261	NUT-HEX
6	5M2894	WASHER-HARD
4	5R9286	CONE-CRUSH
2	5S0003	NUT-FULL
8	6I4545	SEAL-O RING
5	6V0408	SEAL-BONDED
5	6V1904	SEAL-O RING
2	6V3527	FITTING-FLARED
8	8L2786	SEAL-O-RING
8	9M1974	WASHER-HARD
4	9S8752	NUT-FULL
2	0019440	ADAPTER-STR
2	0307942	ADAPTER-ELBOW
2	0307947	ADAPTER-ELBOW
2	0307950	ADAPTER-ELBOW
8	1921405	NUT
8	1921406	FERRULE
4	2147568	SEAL-O-RING-STOR
2	2385082	SEAL-O-RING-STOR
1	2675286	FILTER AS
4	3685086	PIPE-OIL SIPHON
1	3938138	MANIFOLD AS
1	3938139	MANIFOLD AS
1	3946405	HOSE AS
1	3946406	HOSE AS
1	3946407	HOSE AS
1	3946408	HOSE AS
1	3946409	HOSE AS
1	3961560	TUBE AS
1	3961561	TUBE AS
1	3963313	BRACKET AS
1	3963314	BRACKET AS
1	3963320	HOSE AS
2	3983123	HOSE AS
6	3995862	BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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.
*****Group 2*****
6	0L1143	BOLT
2	0S1591	BOLT
6	0S1594	BOLT
2	1B7182	BOLT
4	2B2695	BOLT
10	3V3308	WASHER-HARD
4	5C7261	NUT-HEX
6	5M2894	WASHER-HARD
4	5R9286	CONE-CRUSH
2	5S0003	NUT-FULL
8	6I4545	SEAL-O RING
5	6V0408	SEAL-BONDED
5	6V1904	SEAL-O RING
2	6V3527	FITTING-FLARED
8	8L2786	SEAL-O-RING
8	9M1974	WASHER-HARD
4	9S8752	NUT-FULL
2	0019440	ADAPTER-STR
2	0307942	ADAPTER-ELBOW
2	0307947	ADAPTER-ELBOW
2	0307950	ADAPTER-ELBOW
8	1921405	NUT
8	1921406	FERRULE
4	2147568	SEAL-O-RING-STOR
2	2385082	SEAL-O-RING-STOR
1	2675286	FILTER AS
4	3685086	PIPE-OIL SIPHON
1	3938138	MANIFOLD AS
1	3938139	MANIFOLD AS
1	3946405	HOSE AS
1	3946406	HOSE AS
1	3946407	HOSE AS
1	3946408	HOSE AS
1	3946409	HOSE AS
1	3961561	TUBE AS
1	3963313	BRACKET AS
1	3963314	BRACKET AS
1	3963320	HOSE AS
2	3983123	HOSE AS
6	3995862	BRACKET AS
1	4248392	TUBE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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.
*****Group 3*****
6	0L1143	BOLT
26	0S1588	BOLT
31	0S1591	BOLT
6	0S1594	BOLT
2	1B7182	BOLT
7	1S4974	SEAL-O RING
4	2B2695	BOLT
53	3V3308	WASHER-HARD
4	5C7261	NUT-HEX
30	5M2894	WASHER-HARD
4	5R9286	CONE-CRUSH
2	5S0003	NUT-FULL
7	6I4545	SEAL-O RING
16	6V0408	SEAL-BONDED
2	6V3527	FITTING-FLARED
8	8L2786	SEAL-O-RING
18	8S9191	BOLT
8	9M1974	WASHER-HARD
4	9S8752	NUT-FULL
2	0019440	ADAPTER-STR
4	0307947	ADAPTER-ELBOW
2	0307950	ADAPTER-ELBOW
1	1532781	FITTING
8	1707069	PLUG-BSPP
8	1921405	NUT
8	1921406	FERRULE
4	2147568	SEAL-O-RING-STOR
2	2385082	SEAL-O-RING-STOR
1	2675286	FILTER AS
4	3685086	PIPE-OIL SIPHON
7	3704569	COVER-CYL BLOCK
3	3826662	VALVE-EXPLN RLF
1	3932800	HOSE AS
1	3938138	MANIFOLD AS
1	3938139	MANIFOLD AS
1	3961560	TUBE AS
1	3961561	TUBE AS
1	3963313	BRACKET AS
1	3963314	BRACKET AS
1	3963320	HOSE AS
2	3983123	HOSE AS
6	3995862	BRACKET AS
4	4189734	COVER AS
2	4197153	HOSE AS
2	4211789	HOSE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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.
*****Group 4*****
6	0L1143	BOLT
26	0S1588	BOLT
31	0S1591	BOLT
6	0S1594	BOLT
2	1B7182	BOLT
7	1S4974	SEAL-O RING
4	2B2695	BOLT
53	3V3308	WASHER-HARD
4	5C7261	NUT-HEX
30	5M2894	WASHER-HARD
4	5R9286	CONE-CRUSH
2	5S0003	NUT-FULL
7	6I4545	SEAL-O RING
16	6V0408	SEAL-BONDED
2	6V3527	FITTING-FLARED
8	8L2786	SEAL-O-RING
18	8S9191	BOLT
8	9M1974	WASHER-HARD
4	9S8752	NUT-FULL
2	0019440	ADAPTER-STR
4	0307947	ADAPTER-ELBOW
2	0307950	ADAPTER-ELBOW
1	1532781	FITTING
8	1707069	PLUG-BSPP
8	1921405	NUT
8	1921406	FERRULE
4	2147568	SEAL-O-RING-STOR
2	2385082	SEAL-O-RING-STOR
1	2675286	FILTER AS
4	3685086	PIPE-OIL SIPHON
7	3704569	COVER-CYL BLOCK
3	3826662	VALVE-EXPLN RLF
1	3932800	HOSE AS
1	3938138	MANIFOLD AS
1	3938139	MANIFOLD AS
1	3961561	TUBE AS
1	3963313	BRACKET AS
1	3963314	BRACKET AS
1	3963320	HOSE AS
2	3983123	HOSE AS
6	3995862	BRACKET AS
4	4189734	COVER AS
2	4197153	HOSE AS
2	4211789	HOSE AS
1	4248392	TUBE 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

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For engines with 4 inch explosion relief vales, five engine side covers per engine require rework for use with the updated oil mist detection system. Refer to Image1. 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 Eric Neihaus at 864-370-6546 or Neihaus_Eric_W@cat.com. For Petroleum Engines, contact Brad Devorak at 765-448-5046 or Devorak_Brad_C@cat.com.

For engines with 6 inch explosion relief vales, seven new crankcase covers need to be assembled prior to installation on the engine block. Three of the seven covers removed during disassembly should be available as surplus upon rework completion. Refer to Image2. For Marine Engines, contact Eric Neihaus at 864-370-6546 or Neihaus_Eric_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 Procedures for 4 inch and 6 inch configurations.

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Image1

Image2

SERVICE CLAIM ALLOWANCES

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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%
*****Group 1*****
0-200000 hrs, 0-168 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 10.0-hour job for Group 1
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.

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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%
*****Group 2*****
0-200000 hrs, 0-168 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 10.0-hour job for Group 2
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.

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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%
*****Group 3*****
0-200000 hrs, 0-168 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 10.0-hour job for Group 3

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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%
*****Group 4*****
0-200000 hrs, 0-168 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 10.0-hour job for Group 4

PARTS DISPOSITION

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

Rework Procedure

Group Number 1 Group Number 2

- Ensure that five engine side covers per engine being updated are reworked prior to starting this Rework Procedure to the oil mist detector system.

Reference the 394-5195 Oil Mist Detector Group and the (LH) 424-8391 or 395-3256 and (RH) 395-3257 Air Lines Groups.

- 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 (The larger pressure regulator will not be reused 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 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 five covers and set aside for reuse. Remove all eight crankcase covers from this side of the engine to gain access to the suction funnels located in each compartment of the crankcase.

Image1.5.1

- 10) Carefully loosen the connections between the suction funnels and the block. Rotate each as shown in Image1.6.2 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 five locations shown in Image1.7.1 with the machined port positioned in the lower left as shown in Image1.7.2. 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 three crankcase covers that were removed earlier.

Image1.7.1

Image1.7.2

- 12) Using 396-3313 Bracket and 396-3314 Bracket, mount the 144-0526 Regulator. Note new orientation of regulator. Refer to Image1.8.1 for hardware.

- 13) Install the 360-4135 Air Filter, 396-1561 and 424-8392 Tubes (LH mounted), 396-1561 and 396-1560 Tubes (RH mounted). Refer to Image1.8.2 through Image1.8.4 for hardware.

Image1.8.1

Image1.8.2

Image1.8.3

Image1.8.4

Image1.9.1

- 18) Mount engine wall connections into the G3/4 inch side cover ports and tighten to 110 N.m.

- 19) Mount the pipe siphon into the wall connection. Refer to Image 1.10.1 for location information.

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

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

Image1.10.1

- 21) Install fittings into manifolds and attach drain hoses. Refer to Image1.11.1 for hardware.

Image1.11.1

- 22) Calibrate the OMD head. Refer to RENR2225, Testing and Adjusting, "Commissioning Procedure" for Oil Mist Detectors.

Group Number 3 Group Number 4

Reference the 393-6454 Oil Mist Detector Group and the (LH) 424-8391 or 395-3256 and (RH) 395-3257 Air Lines Groups.

- 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).

Image2.1.1

Image2.2.1

Image2.2.2

Image2.3.1

Image2.3.2

- 9) Remove seven of the eight crankcase covers from this side of the engine. Do not remove the crankcase cover that is located behind the engine starter. Keep all crankcase cover bolts and washers for reuse.

Image2.5.1

Image2.5.2

- 11) Install three of the 382-662 Explosion Relief Valves on three of the 370-4569 Crankcase Covers. Refer to Image2.6.1 for completed crankcase covers.

Install four of the 418-9734 Three Port Covers on four of the 370-4569 Crankcase Covers. Each three port cover requires six 5M-2894 Washers and six 0S-1588 Bolts to fasten the three port cover to the 370-4569 Crankcase Covers.

Install the seven crankcase cover assemblies to the block. Reuse the 3V-3308 Washers and 0S-1591 Bolts that were removed during disassembly of the seven crankcase covers. Refer to Image2.6.2 for location of the new crankcase covers for oil mist detectors mounted to either service side of the engine.

Replace the two bolts that mounted the oil collection box with two 0S-1591 Bolts. Reinstall the remaining three crankcase covers that were removed earlier.

Image2.6.1

Image2.6.2

- 12) Using 396-3313 Bracket and 396-3314 Bracket, mount the 144-0526 Regulator. Note new orientation of regulator. Refer to Image2.7.1 for hardware.

- 13) Install the 360-4135 Air Filter, 396-1561 and 424-8392 Tubes (LH mounted), 396-1561 and 396-1560 Tubes (RH mounted). Refer to Image2.7.2 through Image2.7.4 for hardware.

Image2.7.1

Image2.7.2

Image2.7.3

Image2.7.4

- 14) Install the 393-8138 Right Manifold and 393-8139 Left Manifold using eight 192-1406 Ferrules and 192-1405 Nuts.

- 15) Install the new 399-5862 Manifold Support Brackets. Refer to Image2.8.1 for hardware.

- 16) Install new 398-3123 Hose Assemblies between the manifolds and OMD head.

- 17) Install new 393-2800 hose assembly between the cylinder #4 crankcase cover that contains the 418-9734 three port cover and the OMD head. Refer to Image2.8.1 for installation location into the three port cover.

- 18) Using fitting 6V-3527, mount four of the 368-5086 oil-siphons into the threaded bosses, located on the three port side covers. Refer to Image2.8.1 for installation locations of these four oil-siphons.

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

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