PRODUCT IMPROVEMENT PROGRAM FOR REPLACING AUXILIARY COOLING HOSE ON CERTAIN C18 MARINE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING AUXILIARY COOLING HOSE ON CERTAIN C18 MARINE ENGINES

Usage:

REBE7473-00

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07Sep2011

U-374

A-310

D-332

O-325

TM-22

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING AUXILIARY COOLING HOSE ON CERTAIN C18 MARINE ENGINES
1350 1380		PI10873

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10873" 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 "PI10873" 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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PROBLEM

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The auxiliary cooling hose needs to be replaced on certain C18 Marine engines. The existing auxiliary cooling hose can burst and allow sea water to be pumped into the vessel and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C18	CYN00274, 488, 491-492, 518, 603-604 GBM00210-00212, 216-220, 222-268, 271-329, 332-379, 381-382, 386-405, 409-425, 427, 429-442, 444-447, 449-464, 469-471, 475-478, 480-482, 484-487, 489-500 GEN00168, 267, 278-281, 284 GES00194, 208, 213-217, 231-233, 235-238, 243-245, 247, 250-251, 254, 258-263, 265, 268, 280-281, 285, 287-291, 295-297, 800, 802-803, 805, 807-808, 811, 826-829, 831-832, 835-843, 845, 847-848 MGS00892-00898, 900-921 T2P00644-00645, 647, 747, 767, 770, 782, 784, 801-802, 809, 813, 818-819, 821-822, 825-827, 829, 831, 833, 839, 841, 843, 865, 868-869, 872, 874, 878-884, 886, 889, 893, 910, 915, 918-919, 924-925, 927-929, 931-932, 936, 939, 941-942, 944-946, 951-953, 955, 957, 959-963, 965, 968, 971-972, 978, 980-981, 984-985, 987-988, 992-993, 996-1000, 1002, 1006-1007, 1010-1016, 1018, 1021, 1023-1025, 1028-1029, 1031-1032, 1036-1037, 1040-1041, 1043, 1045-1048, 1050, 1056-1057, 1060, 1062, 1064, 1094, 1097-1098, 1103-1105, 1107, 1109, 1111-1113, 1116, 1119-1120, 1124, 1131-1132, 1134, 1138-1139, 1141-1142, 1144-1145, 1149, 1154, 1156-1158, 1162, 1164-1165, 1168-1169, 1171, 1173, 1175-1176, 1178, 1180-1182, 1186-1187, 1189-1193, 1197, 1199, 1205-1206, 1214-1215, 1221, 1223, 1225, 1230, 1232, 1238, 1240, 1246-1247, 1249, 1259, 1267, 1271-1272, 1280-1282, 1285, 1288, 1293, 1295, 1298, 1303-1305, 1315-1318, 1323-1328, 1340, 1343-1345, 1347-1348, 1350-1354, 1356-1361, 1363-1366, 1373-1374, 1376-1377, 1380-1389, 1391-1393, 1398-1399, 1401-1402, 1405-1406, 1410, 1414, 1416-1417, 1419-1422, 1424, 1427-1430, 1432, 1437 WKB00426-00428, 430-433

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*****Group 2*****
C18	CKH00209, 1147, 1150, 1325, 1468, 1611, 1705, 1722, 1816, 1819, 2191, 2507, 2633, 2638, 3109 JKX01122-01123, 1161, 1163 PLE00293 T2P00666, 685, 785, 796, 807, 815, 820, 830, 835, 842, 844, 861, 895, 926, 930, 982, 986, 989, 994, 1065, 1110, 1159, 1179, 1196, 1220, 1234-1235, 1264, 1277-1278, 1291-1292, 1296, 1299, 1309-1310, 1320, 1332, 1362, 1368-1372, 1394-1397, 1407, 1438

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3813801	HOSE
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*****
1	3813842	HOSE
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.

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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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%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.0-hour job for Group 1
On vessels with multiple affected engines every effort should be made to complete the service letter on all engines on the vessel on the same trip. Please reference the other engine serial numbers in the claim story.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.0-hour job for Group 2
On vessels with multiple affected engines every effort should be made to complete the service letter on all engines on the vessel on the same trip. Please reference the other engine serial numbers in the claim story.

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PARTS DISPOSITION

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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

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING AUXILIARY COOLING HOSE ON CERTAIN C18 MARINE ENGINES

MODELS INVOLVED - C18

Dear Caterpillar Product Owner:

The auxiliary cooling hose needs to be replaced on the products listed above. The existing auxiliary cooling hose can burst and allow sea water to be pumped into the vessel and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. 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 07Sep2011 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 07Sep2011 Service Letter

Rework Procedure

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Step 1: Drain the auxiliary cooling system below the level of the hose. Plug (1) in Image1.1.1 can be used.

Note: Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" or refer to Special Publication, PECJ0003, "Caterpillar Shop Supplies and Tools Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Step 2: Remove existing hose (3) in Image1.1.1, between the auxiliary pump elbow and the aftercooler by removing hose clamps (2). Retain hose clamps (2) for reassembly.

Step 3: Install the new reinforced hose and the existing hose clamps (2). Tighten the clamps to a torque of 11 Nm.

Note: Only sea water applications require the use of two hose clamps at each connection.

Step 4: Reinstall plug (1) in Image1.1.1.

Note: Loctite 565 Sealant is recommended for this plug.

Note: Ensure the auxiliary pump is primed before start up to prevent a dry run.