PRODUCT SUPPORT PROGRAM FOR REWORKING THE 217-8464 LEVEL ALARM GROUP ON CERTAIN 3616 AND C280-16 ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE 217-8464 LEVEL ALARM GROUP ON CERTAIN 3616 AND C280-16 ENGINES

Usage:

REBE6283-00

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01Oct2010

U-403

A-320

D-347

O-349

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE 217-8464 LEVEL ALARM GROUP ON CERTAIN 3616 AND C280-16 ENGINES
7422		PS43171

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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 "PS43171" 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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TERMINATION DATE

31Oct2011

PROBLEM

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The existing 2N-9768 Level Switch Assembly is installed approximately 45 mm too high and can generate false oil level alarms on certain 3616 and C280-16 engines.

AFFECTED PRODUCT

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Model	Identification Number
3616	1PD00533-00539, 541-542, 544-545, 548, 550-551, 565-567, 570-573, 575, 578-583, 596-617
C280-16	NKB00116-00120, 122, 124-133, 136-147, 149-188 TDX00128-00132

PARTS NEEDED

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Qty	Part Number	Description
2	4P7481	SPACER
2	5P0537	WASHER-HARD
2	9F7022	BOLT
1	3619520	KIT-OIL LEVEL
68	OIL	ENGINE OIL - REFER TO OMM (68 GALLONS)
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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Relocate the level switch assembly, replace the oil level gauge, and add engine oil to the proper level.

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%
0-3225 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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1. Remove the existing 2A-0762 Bolts, 5P-0537 Washers, and 7E-7731 Mount from the Oil Level Alarm. Retain for reuse.

2. Mark location for new mounting holes approximately 45 mm directly below existing mounting holes.

3. Drill and tap holes to accommodate the existing 7E-7731 Mount, 1/4-20-2A, 9.6 mm long.

4. Install existing 7E-7731 Mounts into drilled and tapped holes. Install 4P-7481 Spacer onto 7E-7731 Mounts and use 9F-7022 Bolts and 5P-0537 Washers to reassemble 2N-9768 Level Switch Assembly, refer to Image1.1.1.

Image1.1.1

5. Re-install 2A-0762 Bolts and 5P-0537 Washers into original holes.

6. Remove existing oil gauge.

7. Install 361-9520 Oil Level Kit. Weld 165-4033 Boss in accordance with Image1.2.1 below.

Image1.2.1

Image1.2.2

Contents of 361-9520 Oil Level Kit:

Item___Part Number_____Description

1 ______ 1W-1415 _______ Gasket
2 ______ 165-4033 ______ Boss
3 ______ 355-3308 ______ Gauge As
4 ______ 355-3310 ______ Gauge As
5 ______ 0S-1621 _______ Bolt 1/2-13
6 ______ 1A-2029 _______ Bolt 3/8-16
7 ______ 1B-8471 _______ Clip
8 ______ 3V-3308 _______ Washer-Hard
9 ______ 5P-8245 _______ Washer-Hard

8. It is necessary to add approximately 68 gallons of Engine Oil to ensure proper engine oil volume. Refer to the appropriate Operation & Maintenance Manual.