PRODUCT IMPROVEMENT PROGRAM FOR RESEALING THE 225-3101 CYLINDER HEAD SPACER PLATE GASKET ON CERTAIN C32 MARINE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR RESEALING THE 225-3101 CYLINDER HEAD SPACER PLATE GASKET ON CERTAIN C32 MARINE ENGINES

Usage:

REBE5857-01

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02Mar2010

(Revised 09Mar2010)

U-76

D-69

O-74

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR RESEALING THE 2253101/">225-3101 CYLINDER HEAD SPACER PLATE GASKET ON CERTAIN C32 MARINE ENGINES
1201 1100 7555		PI31724

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31724" 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 "PI31724" as the Part Number, "7751" as the Group Number, "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 02Mar2010 Service Letter. Changes have been made to Service Claims Allowance and Action Required.

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COMPLETION DATE	TERMINATION DATE
30Sep2010	31Mar2011

PROBLEM

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The 2253101/">225-3101 Gasket-Plate may leak coolant and/or oil from between the spacer plate and the top deck of the cylinder block on certain C32 Marine engines.

An improved procedure for preventing oil and coolant leaks around the 2253101/">225-3101 Gasket-Plate is now available to be used on the engines that are listed in this Service Letter. For improved sealing performance, apply 4C9505 Adheasive Sealant (Loctite 5923 for other geographical regions) to the total surface on both sides of 2253101/">225-3101 Gasket-Plate. The adheasive sealant is used only as a dressing for the gasket.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C32	RNC03088, 3104-3105, 3138, 3145 T3T00105, 107-109, 131-132, 134, 136, 149-150

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*****Group 2*****
C32	RXB03770, 3772, 3789, 3795-3797, 3812, 3815-3826, 3828, 3840 SLT00103-00104

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*****Group 3*****
C32	RXB03496, 3513, 3515, 3527, 3546, 3646, 3652, 3654-3656, 3660, 3663, 3666, 3680, 3728, 3733

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
48	3E6772	SEAL-WATER
2	3P0655	SEAL-O-RING
2	4C9505	SEALANT-GASKET
2	4N1918	GASKET
4	5E8771	SEAL-O-RING
4	5P8356	SEAL-O-RING
2	5S9134	SEAL-O-RING
4	6K6307	SEAL-O-RING
2	6L7817	SEAL-O-RING
12	6V5051	SEAL-O-RING
4	6V6609	SEAL-O-RING
2	7C0307	GASKET
1	8C3089	SEAL-O-RING
12	8S9191	BOLT
2	8T1703	SEAL-O RING
12	9X7317	SEAL-FUEL SYSTEM
1	0618639	SEAL-O-RING
4	1178801	SEAL-O-RING
2	1262702	SEAL-INTEGRAL
12	1299452	GASKET-EXH MANF
2	1986068	SEAL-INTEGRAL
9	2147568	SEAL-O-RING-STOR
2	2226456	SEAL
2	2253099	GASKET-CYL HEAD
2	2253101	GASKET-PLATE
1	2265613	GASKET
12	2303728	SEAL-FUEL SYSTEM
12	2303775	SEAL-FUEL SYSTEM
4	2314708	SEAL-O-RING
1	2388708	GASKET
1	2388709	GASKET
1	2418156	GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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*****
12	0L1143	BOLT
4	1U8846	GASKET MAKER
12	2N7174	GASKET-ADAPTER
12	3E6747	SEAL-O-RING
48	3E6772	SEAL-WATER
2	3E6773	SEAL-O RING
2	3P0655	SEAL-O-RING
4	3S4489	SEAL-O RING
2	4C9505	SEALANT-GASKET
1	4N1156	GASKET
2	4N1918	GASKET
1	4N1946	GASKET
1	4N2564	GASKET-AFTCLR
1	4N3955	GASKET
1	4P8881	GASKET
4	5P8356	SEAL-O-RING
8	6L7817	SEAL-O-RING
8	6V3917	SEAL-O-RING
4	6V5049	SEAL-O-RING
1	6V5134	SEAL-O-RING
12	6V5266	SEAL-O-RING
6	7C0307	GASKET
2	7L4773	SEAL-O-RING
2	7M7273	GASKET-TURBO
1	8S5543	GASKET
12	9X7681	SEAL-O-RING
1	9X7734	SEAL-O-RING
2	0336027	SEAL-O-RING
12	0336034	SEAL-O-RING
12	0618561	SEAL-O-RING
1	0619456	SEAL-O-RING
24	1079570	SEAL-O RING
1	1085803	SEAL-O-RING
4	1085806	SEAL-O-RING
6	1090076	SEAL-O-RING
2	1121102	SEAL-O-RING
2	1123540	SEAL-O-RING
12	1167220	SEAL-RECTANGULAR
24	1167221	SEAL-RECTANGULAR
12	1167222	SEAL-FUEL SYSTEM
2	1262702	SEAL-INTEGRAL
12	1299452	GASKET-EXH MANF
2	1522938	SEAL-O-RING
2	1522939	SEAL-O-RING
2	1986068	SEAL-INTEGRAL
4	2147568	SEAL-O-RING-STOR
2	2253099	GASKET-CYL HEAD
2	2253101	GASKET-PLATE
1	2348937	SEAL-INTEGRAL
1	2886956	SEAL
2	3385101	SEAL-ISOLATION
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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*****
12	0L1143	BOLT
4	1U8846	GASKET MAKER
12	2N7174	GASKET-ADAPTER
12	3E6747	SEAL-O-RING
48	3E6772	SEAL-WATER
2	3E6773	SEAL-O RING
2	3P0655	SEAL-O-RING
4	3S4489	SEAL-O RING
2	4C9505	SEALANT-GASKET
1	4N1156	GASKET
2	4N1918	GASKET
1	4N1946	GASKET
1	4N2564	GASKET-AFTCLR
1	4N3955	GASKET
1	4P8881	GASKET
4	5P8356	SEAL-O-RING
2	5S9134	SEAL-O-RING
8	6L7817	SEAL-O-RING
8	6V3917	SEAL-O-RING
4	6V5049	SEAL-O-RING
1	6V5134	SEAL-O-RING
12	6V5266	SEAL-O-RING
6	7C0307	GASKET
2	7L4773	SEAL-O-RING
2	7M7273	GASKET-TURBO
1	8S5543	GASKET
12	9X7681	SEAL-O-RING
1	9X7734	SEAL-O-RING
2	0336027	SEAL-O-RING
12	0336034	SEAL-O-RING
12	0618561	SEAL-O-RING
1	0619456	SEAL-O-RING
24	1079570	SEAL-O RING
1	1085803	SEAL-O-RING
4	1085806	SEAL-O-RING
6	1090076	SEAL-O-RING
2	1121102	SEAL-O-RING
2	1123540	SEAL-O-RING
12	1167220	SEAL-RECTANGULAR
24	1167221	SEAL-RECTANGULAR
12	1167222	SEAL-FUEL SYSTEM
2	1262702	SEAL-INTEGRAL
12	1299452	GASKET-EXH MANF
2	1522938	SEAL-O-RING
2	1522939	SEAL-O-RING
1	1955168	GASKET
2	1986068	SEAL-INTEGRAL
4	2147568	SEAL-O-RING-STOR
1	2200756	GASKET
2	2253099	GASKET-CYL HEAD
2	2253101	GASKET-PLATE
12	2300940	SEAL
1	2348937	SEAL-INTEGRAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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NOTE: The Affected Product have been identified as being in Dealer Inventory. This program is to be applied prior to installation in a vessel.

1. Follow Disassembly and Assembly instructions as outlined in RENR8628 for (RNC-T3T)engines or SENR5031 for (RXB-SLT) engines to remove and install the cylinder heads on the engine.

2. Remove all previous material from mating surfaces of the cylinder heads and the cylinder block.

NOTE: Wear rubber gloves when working with solvents and Adhesive Sealants.

3. For best results, clean and dry all surfaces with a solvent such as brake cleaner that is free of residue.

4. Apply 4C9505 Adhesive Sealant (Loctite 5923 for other geographical regions) to the side of the 2253101/">225-3101 plate gasket that faces the cylinder block surface.

5. Spread the 4C9505 Adhesive Sealant (Loctite 5923 for other geographical regions) with a spatula to a uniform thin layer of less than 1 mm (0.04 inch) across the 2253101/">225-3101 Plate Gasket. Do not allow the 4C9505 Adheasive Sealant (Loctite 5923 for other geographical regions) to be placed on the contact surfaces of the 3E-6772 Seal.

6. Position the gasket on the cylinder block assembly. Coat the second side of 2253101/">225-3101 gasket with 4C9505 Adheasive Sealant (Loctite 5923 for other geographical regions)and again spread the sealant with a spatula to a uniform thin layer of less than 1 mm (0.04 inch) and assemble the cylinder head to the engine before sealant starts to dry or cure.

After the repairs are completed and the sealant has adequate time to cure, the engine can be run.

Cleanup:
The product can be removed from metal surfaces with isopropyl alcohol. If the sealant has been dried for a long time or at high temperatures, it can be removed with a razor knife or putty knife.

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OWNER NOTIFICATION

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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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 35.0-hour job for Group 1
NOTE: The Affected Product have been identified as being in Dealer Inventory. This program is to be applied prior to installation in a vessel.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 35.0-hour job for Group 2
NOTE: The Affected Product have been identified as being in Dealer Inventory. This program is to be applied prior to installation in a vessel.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 35.0-hour job for Group 3
NOTE: The Affected Product have been identified as being in Dealer Inventory. This program is to be applied prior to installation in a vessel.

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.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR RESEALING THE 2253101/">225-3101 CYLINDER HEAD SPACER PLATE GASKET

MODELS INVOLVED - C32 Marine Engines

Dear Caterpillar Product Owner:

The cylinder head needs to be resealed on the products listed below. The existing 2253101/">225-3101 spacer plate gasket can leak oil or coolant. 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 02Mar2010 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 02Mar2010 Service Letter