PRODUCT SUPPORT PROGRAM FOR REPLACING THE OIL MIST DETECTOR ON 3516, 3516B, 3516C, AND 3516C HD ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE OIL MIST DETECTOR ON 3516, 3516B, 3516C, AND 3516C HD ENGINES

Usage:

REBE9158-03

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07Feb2013

(Revised 24Jul2013)

U-44

A-35

D-40

O-43

TM-1

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE OIL MIST DETECTOR ON 3516, 3516B, 3516C, AND 3516C HD ENGINES
1336		PS43831

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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 "PS43831" 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 07Feb2013 (Revised 12Apr2013) Service Letter. Changes have been made to the Affected Product, Parts Needed, Service Claim Allowances, and Rework Procedure.

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TERMINATION DATE

28Feb2015

PROBLEM

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The existing Oil Mist Detector (OMD) group may be susceptible to an inadvertent engine shutdown, or the engine not shutting down appropriately. The affected OMD groups include 267-2716 (used on Tier 2 Engines), 318-8119 (used on Tier 2 Engines), and 388-0328 (used on Tier 3 Engines).

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3516	25Z07115
3516B	PAG00110-00111, 126, 131-132, 137, 139-140, 145, 159, 187, 191, 195, 198-201, 212, 218, 224, 226-228, 231, 253-256, 313-316, 326, 328, 332-333, 347-348, 384-386, 389, 393-394, 401-412, 421-423, 439, 441 S2X00602, 604
3516C	JTS00110-00111, 116-117, 122-124, 129-143, 148-153, 166-167, 180, 182, 184-185, 200-203, 258, 274-277, 279, 281-282, 284-294, 298-301, 303-304, 306, 308-382 TTJ00200, 249-257, 260-263, 266-269, 271, 273, 294-299, 303-317, 322-335, 338-344, 348-349, 351-357, 364-369, 376-377, 380-383, 403-404, 406

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*****Group 2*****
3516C HD	TKX00200-00201 TKY00200-00203, 208-211

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
4	0L2070	BOLT
1	0S1588	BOLT
24	0S1594	BOLT
1	0S1617	BOLT
5	0S1618	BOLT
17	1A2029	BOLT
2	1N2914	COVER-CYL BLK SI
1	1W8129	SUPPORT
1	2T2170	ADAPTER-ELBOW
1	2W0752	GASKET
8	3B1915	BOLT
8	3E4352	WASHER-HARD
12	3J1907	SEAL-O-RING
1	3P0653	SEAL-O-RING
1	3P0655	SEAL-O-RING
1	4D7735	CLIP
2	4N1320	GASKET-ADAPTER
1	4W0530	RING-RETAINING
4	5G3676	GROMMET
25	5M2894	WASHER-HARD
4	5P7970	NUT-HEX
1	5P8245	WASHER-HARD
3	5S0003	NUT-FULL
1	6J2244	SEAL-O-RING
6	6V0408	SEAL-BONDED
1	6V1454	SEAL-O RING
4	6V3527	FITTING-FLARED
1	6V3908	SEAL-O-RING
4	6V3918	BOLT-HEX HEAD
5	6V5066	SEAL-O RING
26	6V8397	SEAL-O-RING-ORFS
6	6V8724	ADAPTER-ELBOW 90
5	6V8730	ADAPTER-STR
2	6V9001	ADAPTER-ELBOW
1	7N4932	GASKET
1	7N4945	GASKET
1	8B9725	BOSS
1	8C3107	SEAL-O-RING
2	8I3633	ADAPTER AS-STR
6	8L2786	SEAL-O-RING
1	8N9993	COVER-CAMSHAFT
4	8T1889	CLIP-2 PIECE
4	8T1890	CLIP-2 PIECE
1	8T1905	ADAPTER-ELBOW
2	8T7877	SEAL-O-RING
9	9M1974	WASHER-HARD
4	9M4594	SPACER
1	9S1366	BOLT
2	9S8752	NUT-FULL
32	9X6458	WASHER-HARD
2	1058901	GASKET
1	1092332	SEAL-O-RING
1	1113820	RING - RETAINER
8	1195025	SCREW-FLAT HEAD
1	1343987	CLIP-LOOP
1	1539963	RING
1	1558994	ADAPTER AS-STR
2	1626816	SEAL-FLAT FACE
3	1653930	BOLT-HEX HEAD
2	1653936	BOLT-HEX HEAD
5	1916502	ADAPTER-STR
5	1921404	UNION-FITTING
4	1984766	WASHER-HARD
2	2147568	SEAL-O-RING-STOR
1	2287090	SEAL-O-RING-ORFS
4	2377623	SEAL-O-RING
2	2501416	ADAPTER-LATL TEE
1	2675286	FILTER AS
1	2720758	SEAL
8	2720759	SEAL
3	3603692	PLUG-HD STOR
1	3603693	PLUG-HD STOR
2	3685086	PIPE-OIL SIPHON
1	3880329	TUBE AS
1	3880330	TUBE AS
1	3880331	HOSE AS
1	3898626	PLATE AS
2	3898632	TUBE AS
1	3909164	HOSE AS
2	3919264	COVER
4	3919265	COVER
5	3920875	PIPE-FUNNEL
1	3969872	HOSE AS
1	3969873	HOSE AS
1	3969874	HOSE AS
2	3969875	HOSE AS
1	3969876	TUBE AS
1	3981879	BRACKET AS
1	3981880	BRACKET AS
1	3981913	BRACKET AS
4	3985121	TUBE AS
1	3985209	HOSE AS
1	3985210	BRACKET
1	3985212	HOSE AS
1	3985214	HOSE AS
1	3985215	HOSE AS
1	3985216	HOSE AS
1	3986777	BRACKET AS
1	4174686	HOSE AS
1	4177777	BRACKET AS
1	4195012	BRACKET AS
1	4195075	BRACKET AS
1	4195110	PLATE
1	4195711	BRACKET AS
1	4196694	HOSE AS
1	4259220	DETECTOR HEAD
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*****
4	0L2070	BOLT
1	0S1617	BOLT
14	1A2029	BOLT
2	1N2914	COVER-CYL BLK SI
1	1W8129	SUPPORT
1	2W0752	GASKET
8	3B1915	BOLT
14	3J1907	SEAL-O-RING
1	3P0653	SEAL-O-RING
1	3P0655	SEAL-O-RING
2	4N1320	GASKET-ADAPTER
1	4W0530	RING-RETAINING
4	5G3676	GROMMET
21	5M2894	WASHER-HARD
1	5P8245	WASHER-HARD
3	5S0003	NUT-FULL
1	6J2244	SEAL-O-RING
6	6V0408	SEAL-BONDED
1	6V1454	SEAL-O RING
4	6V3527	FITTING-FLARED
1	6V3908	SEAL-O-RING
5	6V5066	SEAL-O RING
22	6V8397	SEAL-O-RING-ORFS
1	6V9001	ADAPTER-ELBOW
2	6V9832	CAP-ORFS
1	7N4932	GASKET
1	7N4945	GASKET
1	8B9725	BOSS
1	8C3107	SEAL-O-RING
5	8L2786	SEAL-O-RING
1	8N9993	COVER-CAMSHAFT
1	8T0075	ADAPTER-STR
4	8T1889	CLIP-2 PIECE
4	8T1890	CLIP-2 PIECE
2	8T7877	SEAL-O-RING
2	8T9041	ADAPTER-STR
9	9M1974	WASHER-HARD
4	9M4594	SPACER
1	9S1366	BOLT
2	9S8752	NUT-FULL
8	9X6458	WASHER-HARD
2	1058901	GASKET
1	1092332	SEAL-O-RING
1	1113820	RING - RETAINER
1	1343987	CLIP-LOOP
1	1539963	RING
1	1558994	ADAPTER AS-STR
3	1653930	BOLT-HEX HEAD
2	1653936	BOLT-HEX HEAD
5	1921404	UNION-FITTING
1	1974640	HOSE AS.
4	1984766	WASHER-HARD
1	2287090	SEAL-O-RING-ORFS
4	2377623	SEAL-O-RING
1	2720758	SEAL
8	2720759	SEAL
3	3603680	PLUG-HD STOR
3	3603692	PLUG-HD STOR
1	3736713	COVER
1	3880329	TUBE AS
1	3880330	TUBE AS
1	3969875	HOSE AS
1	3969876	TUBE AS
1	3985210	BRACKET
1	4161893	HOSE AS
1	4185550	HOSE AS
1	4186624	BRACKET AS
1	4186625	BRACKET AS
1	4195012	BRACKET AS
1	4195110	PLATE
1	4195711	BRACKET AS
1	4196694	HOSE AS
1	4197166	BRACKET AS
1	4197167	BRACKET AS
1	4259220	DETECTOR HEAD
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.

ACTION REQUIRED

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Remove the current OMD unit and replace with new 5-port OMD unit.

Refer to the attached Rework Procedure.

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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*****
0-20000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 19.5-hour job for Group 1 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.

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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*****
0-20000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 15.0-hour job for Group 2 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.

PARTS DISPOSITION

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

Rework Procedure

Group Number 1

Perform all steps necessary to prepare the engine for safely removing the old OMD system, and re-installing the new updated OMD system. Perform each step carefully as certain items will be reused when installing the new OMD.

1. This procedure will consist of disconnecting and not reusing all original brackets, collection box, side covers, sampling funnels, manifolds, tube assemblies and hoses. (Unless otherwise noted)

2. The 335-8746 Detector Assembly, 144-0526 Regulator and 7E-9324 Spring Mounts from the original system will be reused.

3. Disconnect the hose(s) connected to the detector and regulator. Disassemble the detector, regulator and spring mounts from mount plate and retain for reuse.

4. Remove and do not reuse all eight of the 291-0654 Covers, Pip Seals, Sampling Funnels and Mounting Hardware

5. Remove and do not reuse the bracket, which mounts the OMD to the engine. The remainder of bracket that was left attached to engine in Step 3.

6. Remove and do not reuse 263-3686 Valve Assembly and connecting hoses. Refer to Image 1.3.1.

Image1.2.1

Installing New Oil Mist Detector on Tier 2 Engines

7. Install the 392-0875 Sampling Funnel to the 391-9265 OMD Side Covers using a 191-6502 Adapter Fitting and a 192-1404 Compression Fitting Assembly. Assemble these covers to cylinder number 1, 7, 11 and 15. Install sampling funnel to only one of 391-9264 OMD Side Cover and assemble at cylinder number 5. Install the 391-9264 Cover without sampling funnel at cylinder number 9. Install the 368-5086 Pipe Siphon to cylinder covers number 5 and 9.

Note: Must be tightened to 35 +/- 5 Nm. Verify that the sampling funnel is not moving and does not come loose. Be sure to fill the siphon with 70mL of engine oil. DO NOT over fill ? over filling will cause draining effect resulting in improper operation.

Image1.3.1

8. Use new set of 9X-8872 Bolts to install the new OMD side covers. Be sure to use new set of bolts as these are self-locking. There should be two plain 1N-2914 Side covers located at cylinders number 3 and 13. The new OMD will utilize only five sample points compared to the previous model, which used eight ports.

9. Install the 388-0329 Rear Manifold assembly using 419-7167 and 419-7166 Brackets. Install the 388-0330 Front Manifold assembly using 418-6624 and 418-6625 Brackets. The manifold assemblies are held up with 8T-1889 and 8T-1890 2-Piece Clip and 1A-2029 Bolt and 5M-2894 Washer be sure to use a 5G-3676 Grommet between the 2-piece clips.

10. Install a 419-5711 Lower Support Bracket to the engine block using 0L-2070 Bolts. Refer to Image 1.5.3.

11. Install 1W-8129 Cast bracket to engine block using 165-3936 Bolts.

12. Mount 419-5012 Main Detector bracket to lower support and cast brackets.

13. Reuse the previously removed 7E-9324 Spring Mount to mount the 389-8626 Bracket to the detector main bracket.

14. Mount the 144-0526 Regulator and 267-5286 new Air filter to 389-8626 Bracket. Connect the Air filter outlet to regulator inlet using 399-0331 Hose. Connect Regulator outlet to detector air inlet using 390-9164 Hose.

Note: Must be tighten to 28 +/- 7 N.m.
Note: The directional arrow on the air filter should point towards the rear of the engine.

Image1.4.1

15. Install the OMD exhaust line using 419-6694 Hose Assembly, 419-5110 Plate, 8N-9993 Cover and 6V-3527 Adapter. Refer to Image 1.6.1.

16. Mount the previously removed 335-8746 Oil Mist Detector to 389-8626 Bracket.

Be sure to connect the following:
a) Oil Mist Connection (1/2 BSPP)
b) Oil Mist Connection (3/4 BSPP) - Two of them, one on each side of the OMD.
Note: Tighten to 110 Nm.
c) Drain Connection (3/4 BSPP)
d) Regulator Air Inlet (1/2 BSPP)

17. Install hoses per layout shown in Image 1.6.2. It is important to connect identified hoses to the OMD side covers and identified ports on the manifolds for proper functioning of the system. Use 360-3692 Plug to seal unused ports on manifolds.

Image1.5.1

Image1.5.2

Image1.5.3

18. Remove the detector head from 335-87846 Main Detector. Install a new 425-9220 Detector Head to the main detector.

Note: Refer to RENR2225, Testing and Adjusting, "Commissioning Procedure" for Oil Mist Detectors.

19. Connect a U-tube manometer at inspection cover.

20. Switch on compressed air supply with inlet pressure in a range from 2 to 15 bar (before connecting the OMD the first time check the pressure).

21. If the negative suction pressure is already adjusted to 60 mm WC within a tolerance of +/-5 mm remove the U-tube manometer and finish the procedure. Otherwise loosen counter-nut. Turn the setscrew until the negative pressure is only 60 mm WC. Note: You could use a magnehelic gauge.

Image1.6.1

Image1.6.2

Group Number 2

Tier 3 Engines:

Perform all steps necessary to prepare the engine for safely installing the new OMD system.

1. Perform Steps 1 through 7 from Group Number 1, except do not remove the OMD side covers and its sampling funnels from cylinders number 1, 5, 7, 9, 11 and 15. Retain the following for reuse.
a) 191-6502, 8I-3633, 2T-2170, 6V-8724, 6V-8730 Adapter
b) 0S-1618, 6V3918 Bolt
c) 335-8746 Detector
d) 250-1416 Elbow
e) 267-5286 Air Filter Assembly
f) 117-3245, 388-0331, 389-8626, 389-8631, 389-8632, 389-8633, 390-9158, 390-9160, 390-9161, 390-9163, 390-9164, and 392-0875 Hose Assembly
g) 7E-9324 Mount
h) 5P-7970 Hex Nut
i) 389-8626 Plate Assembly
j) 144-0526 Regulator
k) 119-5025 Flat Head Screw
l) 389-8631, 389-8632 Tube Assembly
m) 3E-4352 Washer Hard

2. Remove the items below.

a) Remove and do not reuse the sampling line hoses and 389-8631 Tubes that connect cylinder number 3, 9 and 13. Retain CCV line connected to cylinder number 3 for reuse.
b) Remove and do not reuse OMD Side covers and associated 392-0875 Sampling Funnels from clyinder number 3 and 13.

3. Disconnect hoses from Manifold assembly and do not reuse 388-0329 and 388-0330 Manifold Assemblies.

4. Remove and do not reuse 389-8625 Detector Mounting Bracket, 392-0872, 389-8627, 392-0873 and 389-8630 Manifold Mounting Brackets and 7N-6986 Bracket.

Note: Use Tier 2 installation for reference.

5. Remove OMD cover from cylinder number 9. Disassemble and do not reuse the sampling funnel from it. Install back the OMD cover and use 360-3692 Plug to close sampling port on the cover.

6. Install 373-6713 Side Cover to cylinder number 3 and connect the CCV line to port on cover. Install 1N-2914 Side Cover to cylinder number 13. The new OMD system will utilize only five sample points compared to the previous model.

Note: To be tightened to 35 +/- 5 NM. Install 272-0759 PIP Seal to OMD cover prior to installation

7. Assemble detector mount brackets (Image 2.3.1 and Image 2.3.2)
a) Install 419-5711 Lower Support Bracket to the engine block using 0L-2070 Bolts.
b) Install 1W-8129 Cast Bracket to engine the block using 165-3936 Bolts.
c) Mount the 419-5012 Main Detector Bracket to lower support and cast brackets.

Image2.3.1

Image2.3.2

8. Assemble the 389-8626 Plate to the main detector bracket using 7E-9324 Spring Mount. Install 335-8746 Detector, 144-0526 Regulator and 267-5286 Air filter Assembly. Connect the air filter outlet to regulator inlet using 399-0331 Hose. Connect the regulator outlet to detector air inlet using 390-9164 Hose. The detector head should be replaced with 425-9220 Detector Head. Note: Tighten to 28 +/- 7 N.m.

Note: The directional arrow on the air filter should point towards the rear of engine.

9. Install 388-0329 Rear manifold assembly, using 419-7167 and 419-7166 Brackets.
Install 388-0330 Front Manifold assembly, using 418-6624 and 418-6625 Brackets. The manifold assemblies are held up with 8T-1889 and 8T-1890 2-Piece Clip and 1A-2029 Bolt and 5M-2894 Washer. Be sure to use 5G-3676 grommet between the 2-piece clips.

10. Re-install hoses per layout shown in picture below. It is important to connect identified hoses to the OMD side covers and identified ports on the manifolds for proper functioning of the system. Connect the CCV Line Adapter to the port on cylinder number 3. Use 360-3692 Plug to seal unused ports on manifold.

11. Connect the 191-6502, 8I-3633, 2T-2170, 6V-8724, 6V-8730 Adapters, 0S-1618, 6V3918 Bolts, 117-3245, 418-5550, 390-9158, 390-9163, 416-1893, 389-8631, 197-4640, 389-8633, 390-9160, 390-9161, 419-6694 Hose Assembly and 389-8631, 396-9876 and 389-8632 Tube assemblies to the OMD cover on cylinder number 1, 5, 7, 9, 11 and 15
Note: Verify the fittings are turned in such way that hose are not stressed

Image2.4.1

12. Install the OMD exhaust line using 419-6694 Hose assembly, 419-5110 Plate, 8N-9993 Cover and 6V-3527 Adapter.

Image2.5.1

13. Connect a U-tube manometer at inspection cover.

14. Switch on the compressed air supply with inlet pressure in a range from 2 to 15 bar. Before connecting the OMD the first time check the pressure.

15. If the negative suction pressure is already adjusted to 60 mm WC within a tolerance of +/-5 mm remove the U-tube manometer and finish the procedure. Otherwise loosen counter-nut. Turn setscrew until the negative pressure is only 60 mm WC.
Note: You could use a magnehelic gauge.

16. Calibrate the OMD head. Refer to RENR2225, Testing and Adjusting, "Commissioning Procedure" for oil mist detectors.