PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE AIR INTAKE HOSE NEEDS TO PREVENT HIGH ENGINE OIL CONSUMPTION OR TURBOCHARGER FAILURE ON CERTAIN 365B L EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE AIR INTAKE HOSE NEEDS TO PREVENT HIGH ENGINE OIL CONSUMPTION OR TURBOCHARGER FAILURE ON CERTAIN 365B L EXCAVATORS

Usage:

SEBE8168

September 25, 2002
AU-193
S-192
H-190

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE AIR INTAKE HOSE NEEDS TO PREVENT HIGH ENGINE OIL CONSUMPTION OR TURBOCHARGER FAILURE ON CERTAIN 365B L EXCAVATORS
1051 1058		PI30384

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30384" 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 "PI30384" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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
March 31, 2003	September 30, 2003

PROBLEM

The air intake hose needs to be reworked to prevent high engine oil consumption or turbocharger failure on certain 365B L Excavators. The air intake 1626167 Hose Assembly may interfere with the 1588232 Back-Pressure Check Valve and cause the hose to fail, resulting in engine high oil consumption or turbocharger failure. The 1477095 Pipe Assembly needs to be replaced by a new 2175609 Pipe Assembly to eliminate the interference.

AFFECTED PRODUCT

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Model	Identification Number
365B L	AGD218-249

PARTS NEEDED

1 - 1626167 Hose
1 - 2175609 Pipe Assembly
1 - 2187997 Angle

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

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%	2	0	0	0	0
NOTE: This is a 2-hour job.

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)

SAMPLE OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - The Air Intake Hose Needs To Be Reworked To Prevent High Engine Oil Consumption or Turbocharger Failure

MODELS INVOLVED - 365B L Excavators

Dear Caterpillar Product Owner:

The air intake hose needs to be reworked to prevent high engine oil consumption or turbocharger failure on certain 365B L Excavators. The air intake existing hose assembly may interfere with the back pressure check valve and cause the hose to fail. This may result in engine high oil consumption or turbocharger failure. The existing pipe assembly needs to be replaced with a new pipe assembly to eliminate the interference. New pipe assemblies need to be installed on the products listed below. 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 September 25, 2002 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 September 25, 2002 Service Letter

Rework Procedure

Remove the 1385351 Cover Assembly (at top of the main control valve) to access the air intake pipes and hoses.
Remove the 1385521 Sheet Assembly. Reference Illustration 1.

Illustration 1

Unfasten the two clamps at ends of the 1477095 Pipe Assembly. Remove the 1477143 U-Bolts and 1385448 Angle, which secure the 1477095 Pipe Assembly. Remove the 1477095 Pipe Assembly. Reference Illustration 2.

Illustration 2 - Removal of 1477095 Pipe Assembly

Remove the 1385532 and 1385529 Sheets. See Illustration 3.

Illustration 3 - Removal and modification of sheet assemblies

Inspect the 1477095 Hose Assembly for wear. Replace if needed. Orient the angle of the 1477095 Hose Assembly upward by loosening the clamp at the air cleaner. Install a new 2175609 Pipe Assembly and 2187997 Angle.
If necessary, cut off a part of 1385532 and 1385529 Sheet Assemblies to ensure the clearance between the 1626167 Hose and the 1588232 Back Pressure Check Valve is over 30 mm (1 3/16"). Reference Illustration 4.