PRODUCT SUPPORT PROGRAM FOR UPDATING THE OIL MIST DETECTOR ON CERTAIN 3606, AND C280-6 MARINE ENGINES Caterpillar


PRODUCT SUPPORT PROGRAM FOR UPDATING THE OIL MIST DETECTOR ON CERTAIN 3606, AND C280-6 MARINE ENGINES

Usage:

REBE9097-01

20Nov2012
(Revised 05Aug2013)


O-571
TM-7

 

Before/After

  
  

PRODUCT SUPPORT PROGRAM FOR UPDATING THE OIL MIST DETECTOR ON CERTAIN 3606, AND C280-6 MARINE ENGINES

1336
PS43763
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 "PS43763" 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.

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.

 
NOTE:

This Revised Service Letter replaces the 20Nov2012 Service Letter. Changes have been made to the Service Claim Allowances.


TERMINATION DATE

30Nov2014

PROBLEM

The existing (RH) 193-0657 Oil Mist Detector and the (LH) 224-0882 Oil Mist Detector groups are susceptible to frequent false positive shutdowns causing the engine to shutdown without warning.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
3606  8RB00855-00856, 882
*******Group  2*******
3606  8RB00853-00854

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 0L1351 BOLT
4 0S0509 BOLT
2 0S1591 BOLT
2 1B7182 BOLT
2 2B2695 BOLT
1 3S8665 CLIP
1 4D7735 CLIP
6 5M2894 WASHER-HARD
4 5R9286 CONE-CRUSH
5 6V0408 SEAL-BONDED
2 6V3527 FITTING-FLARED
4 9L2403 CLIP
2 9M1974 WASHER-HARD
1 9S8752 NUT-FULL
2 0019440 ADAPTER-STR
4 0307947 ADAPTER-ELBOW
2 0307950 ADAPTER-ELBOW
6 1921405 NUT
6 1921406 FERRULE
4 2147568 SEAL-O-RING-STOR
2 2385082 SEAL-O-RING-STOR
1 2675286 FILTER AS
4 3685086 PIPE-OIL SIPHON
1 3933586 MANIFOLD AS
1 3933587 MANIFOLD AS
1 3961561 TUBE AS
1 3963215 TUBE AS
1 3963313 BRACKET AS
1 3963314 BRACKET AS
1 3963320 HOSE AS
4 3975347 BRACKET AS
1 3981302 HOSE AS
1 3981303 HOSE AS
2 3981304 HOSE AS
1 3982905 HOSE AS
2 3983123 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 2*******
1 0L1351 BOLT
4 0S0509 BOLT
2 0S1591 BOLT
2 1B7182 BOLT
2 2B2695 BOLT
1 3S8665 CLIP
1 4D7735 CLIP
6 5M2894 WASHER-HARD
2 5R9286 CONE-CRUSH
5 6V0408 SEAL-BONDED
2 6V3527 FITTING-FLARED
4 9L2403 CLIP
2 9M1974 WASHER-HARD
1 9S8752 NUT-FULL
2 0019440 ADAPTER-STR
4 0307947 ADAPTER-ELBOW
2 0307950 ADAPTER-ELBOW
6 1921405 NUT
6 1921406 FERRULE
4 2147568 SEAL-O-RING-STOR
2 2385082 SEAL-O-RING-STOR
1 2675286 FILTER AS
4 3685086 PIPE-OIL SIPHON
1 3933586 MANIFOLD AS
1 3933587 MANIFOLD AS
1 3961561 TUBE AS
1 3962349 HOSE AS
1 3963313 BRACKET AS
1 3963314 BRACKET AS
1 3963320 HOSE AS
4 3975347 BRACKET AS
1 3981302 HOSE AS
1 3981303 HOSE AS
2 3981304 HOSE AS
1 3982905 HOSE AS
2 3983123 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.

ACTION REQUIRED

Five engine side covers per engine require rework for use with the updated oil mist detection system. A limited number of spare covers are available upon request and will be exchanged with the side covers removed during the upgrade. Contact Eric Neihaus (Marine Service Engineer) at 864-370-6546 or Neihaus_Eric_W@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 Procedure.
Image1

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
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.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
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.



PARTS DISPOSITION

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


Rework Procedure


Group Number 1  
 
- 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 (RH) 193-0658 Oil Mist Detector and the (RH) 197-0594 and 298-8507 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 (dispose of the larger pressure regulator 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. The oil collection box will not be reused.
 
- 7) Remove bolts supporting the manifolds.

- 8) Loosen the 192-1405 Nut on each of the suction tubes and carefully remove 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 rework before reuse. Remove all six 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 Image1.6.1 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
 
- 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 crankcase cover that was removed earlier.
Image1.7.1
 
- 12) Using 396-3313 and 396-3314 Brackets, mount the 144-0526 Regulator. Note new orientation of regulator. Refer to Image1.8.1 for hardware.

- 13) Install the 267-5286 Air Filter, 396-3215 Tube Assembly, and the 396-1561 Tube Assembly. Refer to Image1.8.2 and Image1.8.3 for hardware.
Image1.8.1
Image1.8.2
Image1.8.3
 
- 14) Install the 393-3587 Right Manifold and 393-3586 Left Manifold using six 192-1406 Ferrules and 192-1405 Nuts.

- 15) Install the left and right manifold hardware. Refer Image1.9.1 for hardware.

- 16) Install new 030-7947 Fittings, 214-7568 Seals, the four drain hoses located between the manifolds and the oil siphons, and the two drain hoses located between the manifolds and OMD head using the parts set aside for reuse earlier. Refer to Image1.9.2 for hardware.

- 17) Install new fitting in the explosion relief port and hose between the exhaust of the OMD head and the new fitting.

- 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.
Image1.9.1
Image1.9.2
 
- 20) Fill the siphon with 70 mL of engine oil.

- 21) Install fittings into manifolds and attach drain hoses, see Image1.11.1 for part numbers.
 
- 22) Calibrate the OMD head. Refer to RENR2225, Testing and Adjusting, "Commissioning Procedure" for Oil Mist Detectors.
 
 
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 193-0658 Oil Mist Detector (RH) and the (RH) 197-0594 and 298-8507} 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 (dispose of the hose 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).
Image2.2.1
 
- 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 (dispose of the larger pressure regulator 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. The oil collection box will not be reused.
 
- 7) Remove bolts supporting the manifolds.

- 8) Loosen the 192-1405 Nut on each of the suction tubes and carefully remove both manifolds. The 192-1406 Ferrules will not be able to be removed and will not be reused along with the nut and manifolds.
Image2.4.1
Image2.4.2
 
- 9) Carefully remove the explosion relief valves from these five covers and set aside for rework before reuse. Remove all six covers from this side of the engine to gain access to the suction funnels located in each compartment of the crankcase.
Image2.5.1
 
- 10) Carefully loosen the connections between the suction funnels and the block. Rotate each as shown in Image1.6.1 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.
Image2.6.1
 
- 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 crankcase cover that was removed earlier.
Image2.7.1
 
- 12) Using 396-3313 and 396-3314 Brackets, mount the 144-0526 Regulator. Note new orientation of regulator. Refer to Image1.8.1 for hardware.

- 13) Install the 267-5286 Air Filter, 396-3215 Tube Assembly, and the 396-1561 Tube Assembly. Refer to Image2.8.2, and Image2.8.3 for hardware.
Image2.8.1
Image2.8.2
Image2.8.3
 
- 14) Install the 393-3587 Right Manifold and 393-3586 Left Manifold using six 192-1406 Ferrules and 192-1405 Nuts.

- 15) Install the left and right manifold hardware. Refer Image1.9.1 for hardware.

- 16) Install new 030-7947 Fittings, 214-7568 Seals, the four drain hoses located between the manifolds and the oil siphons, and the two drain hoses located between the manifolds and OMD head using the parts set aside for reuse earlier. Refer to Image1.9.2 for hardware.

- 17) Install new fitting in the explosion relief port and hose between the exhaust of the OMD head and the new fitting.

- 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.
Image2.9.1
Image2.9.2
 
- 20) Fill the siphon with 70 mL of engine oil.

- 21) Install fittings into manifolds and attach drain hoses, see Image1.11.1 for part numbers.
 
- 22) Calibrate the OMD head. Refer to RENR2225, Testing and Adjusting, "Commissioning Procedure" for Oil Mist Detectors.
 
 

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