PRODUCT IMPROVEMENT PROGRAM TO INSPECT AND POSSIBLY REPLACE THE NRS COOLER ON CERTAIN C9.3 INDUSTRIAL ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM TO INSPECT AND POSSIBLY REPLACE THE NRS COOLER ON CERTAIN C9.3 INDUSTRIAL ENGINES

Usage:

REBE7899-01

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19Dec2011

(Revised 19Dec2011)

U-564

O-496

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*Priority*	PRODUCT IMPROVEMENT PROGRAM TO INSPECT AND POSSIBLY REPLACE THE NRS COOLER ON CERTAIN C9.3 INDUSTRIAL ENGINES
1251 108C 1061 1087		PI31961

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31961" 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 "PI31961" 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 19Dec2011 Service Letter. Changes have been made to the Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
30Jun2012	31Dec2012

PROBLEM

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The exhaust manifold on the C9.3 engines listed may contain metallic debris that can eventually fail the NRS cooler, causing coolant to enter the engine. This debris is introduced from the exhaust manifold and was not properly cleaned out during the manufacturing process.

AFFECTED PRODUCT

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Model	Identification Number
C9.3	C9N00540-00580, 582

PARTS NEEDED

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Qty	Part Number	Description
2	9N5085	CLAMP-V-BAND
2	3147599	CLAMP-BAND - IF NEEDED
1	3249290	BELLOWS AS
1	3457645	COOLER GP-EXH -B - IF NEEDED
1	3808558	HOSE - IF NEEDED
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 33% 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 attached Rework Procedure.

Make every effort to complete this program prior to the machine reaching 200 hours. Analysis has shown that is a failure is going to occur, it will occur prior to 200 hours.

Note: A Customer Notification Letter will not be sent out with this program.

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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
An additional 8 hrs is allowed to replace the NRS cooler if debris is found. If debris found and the NRS cooler is replaced, please provide photos of the old NRS cooler showing the debris in the claims 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.

Rework Procedure

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NRS Cooler Inspection

1. Record the exhaust manifold machining code from the flange on the exhaust manifold connection at the cylinder 1 exhaust port. Refer to Image1.2.1 and Image1.2.2 for the exact location of the machining code. It may be necessary to use scotch brite to clean rust away from code location. After scrubbing with scotch brite, use a wet cloth and wipe the area. This can bring out the code for better visibility. This can be done without moving any components. Use of a telescoping mirror and flashlight should allow for viewing of the code.

Note: Some codes may be unreadable due to paint or other issues.

Image1.2.1

Image1.2.2

2. Remove brackets or shielding inhibiting access to the NRS cooler bellows.

3. Remove clamps connecting the bellows to the exhaust manifold and the NRS cooler. Soak clamps in penetrating oil prior to removal in order to assist in removal. Refer to Image1.4.1.

Image1.4.1

4. Using 361-5661 Bellows Tool Assembly, remove the bellows from the engines. Refer to Image1.5.1 and Image1.5.2.

Image1.5.1

Image1.5.2

5. Inspect the face of the NRS cooler. Use a flashlight and a magnet to complete a thorough inspection. Image1.6.1 and 1.6.2 provide examples of debris. If debris is found, leave in the NRS cooler and take a picture of location. This image must be attached to claim in SIMSi.

Image1.6.1

Image1.6.2

6. If debris is found, replace the NRS cooler. Refer to the Disassembly and Assembly manual for the proper procedure.

7. If debris is not found, install new 324-9290 Bellows Assembly using
new 9N-5085 Clamps. Tighten the clamps to 7.5 N.m.

Note: The bellow assemblies must be installed in the proper direction. Refer to Image1.8.1.