PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ISOLATION VALVES ON CERTAIN C18 AND C32 MARINE ENGINES
Usage:
TEBE0521-00
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| 14May2014 |
U-271
O-235
TM-11
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| Priority | PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ISOLATION VALVES ON CERTAIN C18 AND C32 MARINE ENGINES |
|
| 7400 1718 1924 1923 1925 1916 1917 1000 1906 | PI32342 |
|
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| NOTE: | This Program must be administered as soon as possible. When reporting the repair, use "PI32342" 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 "PI32342" 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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COMPLETION DATE |
TERMINATION DATE |
| 30Nov2014 | 31May2015 |
PROBLEM
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| The isolation valves needs to be replaced on certain C18 and C32 Marine Engines. The existing isolation valve can leak. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| C32 | SDN00115, 133, 158 |
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| *******Group 2******* | |
| C32 | DSJ00101 SDN00114, 134, 141, 157 |
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| *******Group 3******* | |
| C18 | TNA00108-00109 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 1 | 6V6609 | SEAL-O-RING |
| 1 | 6V9027 | SEAL-O-RING |
| 5 | 7K1181 | STRAP-CABLE |
| 1 | 9S8005 | PLUG-LD STOR |
| 1 | 1834760 | SENSOR GP-PRESS |
| 4 | 2147566 | SEAL-O-RING-STOR |
| 2 | 2147568 | SEAL-O-RING-STOR |
| 1 | 2385080 | SEAL-O-RING-STOR |
| 4 | 2385081 | SEAL-O-RING-STOR |
| 4 | 2746719 | SENSOR GP-PRESS |
| 1 | 3095126 | ADAPTER-TEE |
| 1 | 4370057 | LINE AS-HYBRID |
| 2 | 4378955 | VALVE-ISOLATION |
| 1 | 4378957 | VALVE-ISOLATION |
| 2 | 4378958 | VALVE-ISOLATION |
| 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. |
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| *******Group 2******* | ||
| 1 | 6V6609 | SEAL-O-RING |
| 1 | 6V9027 | SEAL-O-RING |
| 5 | 7K1181 | STRAP-CABLE |
| 1 | 9S8005 | PLUG-LD STOR |
| 1 | 1834760 | SENSOR GP-PRESS |
| 4 | 2147566 | SEAL-O-RING-STOR |
| 2 | 2147568 | SEAL-O-RING-STOR |
| 1 | 2385080 | SEAL-O-RING-STOR |
| 4 | 2385081 | SEAL-O-RING-STOR |
| 4 | 2746719 | SENSOR GP-PRESS |
| 1 | 3095126 | ADAPTER-TEE |
| 1 | 4370055 | LINE AS-HYBRID |
| 2 | 4378955 | VALVE-ISOLATION |
| 1 | 4378957 | VALVE-ISOLATION |
| 2 | 4378958 | VALVE-ISOLATION |
| 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 3******* | ||
| 1 | 6V3250 | SEAL-O-RING |
| 1 | 6V9027 | SEAL-O-RING |
| 7 | 7K1181 | STRAP-CABLE |
| 1 | 0336028 | SEAL-O-RING |
| 1 | 1834760 | SENSOR GP-PRESS |
| 1 | 2147566 | SEAL-O-RING-STOR |
| 1 | 2147567 | SEAL-O-RING-STOR |
| 3 | 2147568 | SEAL-O-RING-STOR |
| 1 | 2287100 | SEAL-O-RING-STOR |
| 5 | 2746719 | SENSOR GP-PRESS |
| 1 | 3770263 | SENSOR-PRESS |
| 1 | 3801097 | VALVE-ISOLATION |
| 5 | 4378955 | VALVE-ISOLATION |
| 1 | 4394479 | VALVE-ISOLATION |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 23% 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. |
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ACTION REQUIRED
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| Refer to the attached Rework Procedure. |
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OWNER NOTIFICATION
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| Owners in the following countries will receive the attached Owner Notification: US Canada |
SERVICE CLAIM ALLOWANCES
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| *******Group 1******* | |||||
| NOTE: This is a 3.0-hour job for Group 1 | |||||
| Travel will only be authorized for one engine for multiple engines being reworked in a boat. Please reference the other engine serial numbers in the claim story. $30 miscellaneous allowance for purchase of paint to match the engine. |
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| *******Group 2******* | |||||
| NOTE: This is a 3.0-hour job for Group 2 | |||||
| Travel will only be authorized for one engine for multiple engines being reworked in a boat. Please reference the other engine serial numbers in the claim story. $30 miscellaneous allowance for purchase of paint to match the engine. |
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| *******Group 3******* | |||||
| NOTE: This is a 3.0-hour job for Group 3 | |||||
| Travel will only be authorized for one engine for multiple engines being reworked in a boat. Please reference the other engine serial numbers in the claim story. $30 miscellaneous allowance for purchase of paint to match the engine. |
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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| EXAMPLE COPY OF OWNER NOTIFICATION XYZ Corporation 3240 Arrow Drive Anywhere, YZ 99999 PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ISOLATION VALVES ON CERTAIN C18 AND C32 MARINE ENGINES MODELS INVOLVED - C18 and C32 Marine Engines Dear Cat Product Owner: The isolation valves needs to be replaced on the products listed below. The existing isolation valve can leak. You will not be charged for the service performed. Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 14May2014 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 14May2014 Service Letter |
| Group Number 1 |
| Before completing the attached Rework Procedure, please review the safety actions in the Operation and Maintenance Manual for the engine. Turn the engine off to allow the oil and fuel pressure to relieve. Drain sea water system. Drain and collect coolant in suitable storage containers for later use, refer to the procedure "Drain the Coolant Systems" in the C32 Marine Engine Operation and Maintenance Manual SEBU8773. |
| Step 1: Remove the existing oil pressure (post-filter) isolation valve and pressure sensor located on the front left had side of the engine block shown as Item 1 in Image 1.2.1. Step 2: Install the 214-7568 O-ring, 437-8955 Valve-Isolation, and 214-7566 O-ring to the engine block shown as Item 1 in Image 1.2.1. Install and connect the 274-6719 Sensor Gp-Pressure to the 437-8955 Valve-Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. |
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| Image1.2.1 |
| Step 3: Remove the existing oil pressure isolation valve(pre-filter)and pressure sensor located behind the oil filters on the left hand side of the engine shown as Item 2 in Image 1.3.1. Step 4: Install the 238-5081 O-ring, 437-8958 Valve-Isolation, and 214-7566 O-ring into the port shown as Item 2 in Image 1.3.1. Install and connect the 274-6719 Sensor Gp-Pressure to the 437-8958 Valve Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. |
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| Image1.3.1 |
| Step 5: Remove the existing jacket water pressure isolation valve and jacket water pressure sensor from the oil cooler bonnet shown as Item 3 in Image 1.4.1. Step 6: Install the 6V-6609 O-ring, 437-8957 Valve-Isolation, and 6V-9027 O-ring into the oil cooler bonnet shown as Item 3 in Image 1.4.1. Install and connect the 183-4760 Sensor Gp-Pressure to the 437-8957 Valve-Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. |
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| Image1.4.1 |
| Step 7: Remove the 353-1316 Line As-Hybrid between the fuel manifold block and the fuel filter base at the location shown in Image 1.5.1. Step 8: Install the 437-0057 Line As-Hybrid between the fuel manifold block and the fuel filter base shown as Item 4 in Image 1.5.1. |
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| Image1.5.1 |
| Step 9: Remove the existing fuel pressure isolation valves and pressure sensors shown at the locations of Item 5 and Item 6 in Image 1.6.1. Step 10: Install the 238-5081 O-ring, 437-8958 Valve-Isolation, and 214-7566 O-ring shown as Item 5 in Image 1.6.1. Install and connect the 274-6719 Sensor Gp-Pressure to the 437-8958 Valve-Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. Step 11: Install the 214-7568 O-ring, 437-8955 Valve-Isolation, and 214-7566 O-ring shown as Item 6 in Image 1.6.1. Install and connect the 274-6719 Sensor Gp-Pressure to the 437-8955 Valve-Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. |
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| Image1.6.1 |
| Step 12: Removed the existing hardware from the fuel filter base port shown as Item 7 in Image 1.7.1. Step 13: Install the 9S-8005 Plug and 238-8005 O-ring into the fuel filter base shown as Item 7 in Image 1.7.1. Step 14: Paint any exposed surfaces. |
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| Image1.7.1 |
| Refill cooling system with collected coolant, refer to the procedure "Fill the Cooling System" in the C32 Marine Engine Operation and Maintenance Manual SEBU8773. Refill sea water system. It may be necessary to prime the sea water pump before operation. Prime the fuel system, refer to the procedure "Fuel System - Prime" in the C32 Marine Engine Operation and Maintenance Manual SEBU8773. |
| Group Number 2 |
| Before completing the attached Rework Procedure, please review the safety actions in the Operation and Maintenance Manual for the engine. Turn the engine off to allow the oil and fuel pressure to relieve. Drain sea water system. Drain and collect coolant in suitable storage containers for later use, refer to the procedure "Drain the Coolant Systems" in the C32 Marine Engine Operation and Maintenance Manual SEBU8773. |
| Step 1: Remove the existing oil pressure (post-filter) isolation valve and pressure sensor located on the front left had side of the engine block shown as Item 1 in Image 2.2.1. Step 2: Install the 214-7568 O-ring, 437-8955 Valve-Isolation, and 214-7566 O-ring to the engine block shown as Item 1 in Image 2.2.1. Connect the 274-6719 Sensor Gp-Pressure to the 437-8955 Valve-Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. Step 3: Remove the existing oil pressure sensor (pre-filter)and pressure sensor located behind the oil filters on the left hand side of the engine shown as Item 2 in Image 1.3.1. Step 4: Install the 238-5081 O-ring, 437-8958 Valve-Isolation, and 214-7566 O-ring into the port shown as Item 2 in Image 2.3.1. Install and connect the 274-6719 Sensor Gp-Pressure to the 437-8958 Valve Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. |
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| Image2.2.1 |
| Step 5: Remove the existing jacket water pressure isolation valve and jacket water pressure sensor from the oil cooler bonnet shown as Item 3 in Image 2.4.1. Step 6: Install the 6V-6609 O-ring, 437-8957 Valve-Isolation, and 6V-9027 O-ring into the oil cooler bonnet shown as Item 3 in Image 2.4.1. Install and connect the 183-4760 Sensor Gp-Pressure to the 437-8957 Valve-Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. |
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| Image2.3.1 |
| Step 7: Remove the 392-8640 Line As-Hybrid between the fuel manifold block and the fuel filter base at the location shown in Image 2.5.1. Step 8: Install the 437-0055 Line As-Hybrid between the fuel manifold block and the fuel filter base shown as Item 4 in Image 2.5.1. |
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| Image2.4.1 |
| Step 9: Remove the existing fuel pressure isolation valves and pressure sensors shown at the locations of Item 5 and Item 6 in Image 2.6.1. Step 10: Install the 238-5081 O-ring, 437-8958 Valve-Isolation, and 214-7566 O-ring shown as Item 5 in Image 2.6.1. Install and connect the 274-6719 Sensor Gp-Pressure to the 437-8958 Valve-Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. Step 11: Install the 214-7568 O-ring, 437-8955 Valve-Isolation, and 214-7566 O-ring shown as Item 6 in Image 2.6.1. Install and connect the 274-6719 Sensor Gp-Pressure to the 437-8955 Valve-Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. |
 |
| Image2.5.1 |
| Step 12: Removed the existing hardware from the fuel filter base port shown as Item 7 in Image 1.7.1. Step 13: Install the 9S-8005 Plug and 238-8005 O-ring into the fuel filter base shown as Item 7 in Image 1.7.1. Step 14: Paint any exposed surfaces. |
 |
| Image2.6.1 |
| Refill cooling system with collected coolant, refer to the procedure "Fill the Cooling System" in the C32 Marine Engine Operation and Maintenance Manual SEBU8773. Refill sea water system. It may be necessary to prime the sea water pump before operation. Prime the fuel system, refer to the procedure "Fuel System - Prime" in the C32 Marine Engine Operation and Maintenance Manual SEBU8773. |
| Group Number 3 |
| Before completing the attached Rework Procedure, please review the safety actions in the Operation and Maintenance Manual for the engine. Turn the engine off to allow the oil and fuel pressure to relieve. Drain sea water system. Drain and collect coolant in suitable storage containers for later use, refer to the procedure "Drain the Coolant Systems" in the C18 Marine Engine Operation and Maintenance Manual SEBU9044. |
| Step 1: Removed the existing jacket water pressure isolation valve and pressure sensor located on the oil cooler bonnet shown as Item 1 in Image 3.2.1. Step 2: Install the 437-8955 Valve-Isolation, 6V-3250 O-ring, and 6V-9027 O-ring in the oil cooler bonnet shown as Item 1 in Image 3.2.1 and in Image 3.2.2. Install and connect the 183-4760 Sensor Gp-Pressure to the 437-8955 Valve-Isolation and existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. Step 3: Remove the existing oil pressure isolation valve and pressure sensor located on the oil inlet line shown as Item 2 in Image 3.2.1. Step 4: Install the 439-4479 Valve-Isolation, 214-7566 O-ring, and 214-7567 O-ring in the oil inlet line of the oil cooler shown as Item 2 in Image 3.2.1 and Image 3.2.3. Connect the 274-6716 Sensor Gp-Pressure to the 439-4479 Valve-Isolation and existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. |
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| Image3.2.1 |
|
|
| Image3.2.1 |
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| Image3.2.2 |
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| Image3.2.3 |
| Step 5: Remove the existing sea water pressure isolation valve and pressure sensor located on the sea water pump outlet elbow shown as Item 3 in Image 3.3.1. Step 6: Install the 380-1097 Valve-Isolation, 033-6028 O-ring, and 228-7100 O-ring in the sea water pump outlet elbow shown as Item 3 in Image 3.3.1. Install and connect the 377-0263 Sensor Gp-Pressure to the 380-1097 Valve-Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. |
 |
| Image3.3.4 |
| Step 7: Remove the existing fuel pressure isolation valves and pressure sensors located on the fuel filter base and fuel pressure regulating manifold shown as Items 4 and 5 in Image 3.4.1. Step 8: Install the 437-8955 Valve-Isolation, 214-7586 O-ring, and 214-7568 O-ring the fuel filter base as shown in Item 4 in Image 3.4.1 and in Image 3.4.2. Install and connect the 274-6719 Sensor Gp-Pressure to the 437-8955 Valve-Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. Step 9: Install the 437-8955 Valve-Isolation, 214-7586 O-ring, and 214-7568 O-ring in the fuel pressure regulating manifold on the fuel filter base as shown in Item 5 in Image 3.4.1 and in Image 3.4.3. Install and connect the 274-6719 Sensor Gp-Pressure to the 437-8955 Valve-Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. |
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| Image3.4.1 |
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| Image3.4.2 |
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| Image3.4.3 |
| Step 10: Remove the existing oil pressure isolation valve and pressure sensor behind the oil filter shown as Item 6 in Image 3.5.1. Step 11: Install the 437-8955 Valve-Isolation, 214-7586 O-ring, and 214-7568 O-ring behind the oil filters shown as Item 6 in Image 3.5.1 and Item 1 in Image 3.5.2. Install and connect the 274-6719 Sensor Gp-Pressure to the 437-8955 Valve-Isolation and the existing harness connection. Use 7K-1181 Strap to secure excess harness to nearest tie strap location. Step 12: Paint any exposed surfaces. Refill cooling system with collected coolant, refer to the procedure "Fill the Cooling System" in the C18 Marine Engine Operation and Maintenance Manual SEBU9044. Refill sea water system. It may be necessary to prime the sea water pump before operation. Prime the fuel system, refer to the procedure "Fuel System - Prime" in the C18 Marine Engine Operation and Maintenance Manual SEBU9044. |
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| Image3.5.1 |
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| Image3.5.2 |
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