Aftercooler Leaks on Certain C4.4 Marine Generator Sets {1063} Caterpillar

Generator Set

C4.4 (S/N: S1M2298-2543,2545-2662,2664-2666,2668-2678,2680-2853,2855-2855,2857-2896,2899-2900,2902-3307,3309-3383,3386-3429,3433-3470,3474-3608,3610-3693,3695-3806,3808-3823,3825-3874,3876-3946,3948-3948,3950-3971,3973-3973,3975-3985,3987-4001,4004-4044,4046-4046,4048-4054,4057-4066,4068-4070,4072-4072,4075-4076,4081-4085,4088-4089,4091-4094,4096-4097,4099-4101,4103-4106,4108-4116,4118-4121,4123-4124,4126-4128,4130-4141,4143-4147,4149-4169,4171-4172,4174-4190,4192-4198,4200-4200,4202-4204,4206-4209,4211-4212,4216-4222,4224-4225,4227-4236,4238-4289,4291-4292,4294-4303,4305-4312,4314-4317,4320-4321,4323-4334,4336-4342,4344-4345,4348-4349,4352-4359,4361-4377,4379-4381,4383-4386,4388-4388,4390-4423,4426-4431,4433-4440,4442-4451,4453-4481,4483-4483,4485-4524,4526-4535,4537-4541,4543-4548,4551-4551,4554-4555,4557-4561,4563-4568,4570-4573,4575-4580,4582-4591,4593-4615,4617-4631,4633-4634,4636-4636,4638-4640,4642-4648,4651-4655,4657-4669,4671-4677,4679-4680,4683-4685,4691-4691,4693-4694,4696-4707,4709-4709,4711-4729,4731-4731,4734-4745,4747-4768,4771-4772,4774-4784,4786-4786,4788-4792,4794-4816,4818-4831,4833-4840,4843-4848,4850-4868,4870-4880,4882-4883,4885-4888,4890-4904,4911-4911,4913-4913,4916-4917,4919-4921,4923-4930,4933-4934,4936-4938,4940-4948,4950-4951,4953-4954,4956-4956,4959-4961,4964-4965,4968-4971,4973-4977,4979-4979,4981-4986,4988-4988,4993-4995,4997-5002,5004-5009,5011-5014,5016-5019,5021-5051,5054-5065,5068-5076,5078-5078,5081-5081,5083-5087,5089-5089,5091-5101,5103-5107,5110-5115,5117-5123,5126-5136,5139-5139,5141-5143,5145-5148,5152-5153,5155-5156,5159-5170,5172-5191,5193-5195,5199-5199,5202-5215,5218-5223,5225-5231,5233-5233,5235-5236,5238-5239,5242-5249,5251-5252,5254-5255,5257-5259,5261-5267,5269-5271,5274-5297,5299-5314,5316-5321,5323-5330,5332-5335,5337-5338,5340-5342,5344-5346,5348-5384,5387-5387,5389-5398,5400-5413,5415-5422,5424-5427,5429-5429,5431-5431,5433-5435,5437-5470,5472-5474,5476-5517,5519-5521,5523-5523,5525-5546,5548-5548,5551-5585,5587-5595,5597-5599,5601-5616,5618-5632,5636-5643,5645-5649,5651-5652,5655-5660,5662-5676,5678-5679,5681-5683,5686-5696,5698-5705,5707-5708,5710-5712,5714-5740,5743-5745,5747-5749,5751-5756,5758-5764,5766-5767,5769-5773,5775-5776,5778-5782,5784-5787,5789-5799,5802-5804,5806-5819,5821-5831,5834-5843,5846-5857,5859-5863,5865-5879,5881-5883,5885-5887,5889-5910,5913-5924,5926-5937,5939-5942,5944-5986,5989-5991,5993-6000,6003-6005,6007-6038,6040-6044,6046-6046,6049-6074,6077-6077,6079-6084,6086-6091,6093-6095,6097-6103,6106-6122,6124-6130,6132-6133,6135-6135,6138-6138,6140-6159,6163-6167,6169-6171,6173-6180,6182-6204,6207-6208,6210-6210,6212-6225,6228-6242,6244-6245,6248-6256,6258-6279,6281-6282,6286-6286,6289-6294,6297-6298,6301-6318,6320-6320,6322-6326,6329-6342,6345-6345,6348-6352,6354-6354,6356-6360,6364-6366,6368-6374,6377-6382,6384-6392,6394-6394,6397-6397,6399-6416,6418-6423,6425-6435,6437-6440,6443-6446,6450-6450,6452-6462,6464-6465,6468-6469,6471-6479,6483-6486,6488-6489,6492-6501,6505-6506,6510-6511,6515-6529,6531-6547,6549-6558,6561-6565,6567-6583,6585-6586,6590-6599,6601-6601,6603-6612,6614-6627,6629-6641,6643-6660,6662-6675,6677-6682,6685-6686,6688-6692,6694-6697,6700-6711,6715-6727,6730-6740,6742-6755,6759-6760,6762-6764,6766-6771,6773-6776,6780-6783,6785-6787,6789-6805,6808-6828,6830-6832,6835-6838,6841-6848,6850-6850,6852-6853,6855-6855,6857-6857,6859-6864,6866-6874,6876-6882,6884-6886,6888-6894,6897-6903,6906-6922,6925-6927,6929-6939,6941-6946,6948-6950,6952-6960,6962-6975,6978-6993,6995-7001,7003-7003,7005-7010,7012-7016,7018-7019,7022-7032,7035-7038,7040-7041,7043-7067,7070-7071,7073-7110,7112-7115,7117-7118,7120-7121,7124-7126,7128-7129,7131-7133,7135-7141,7144-7146,7148-7151,7153-7155,7157-7157,7159-7159,7162-7162,7164-UP)

Problem

There have been some instances where the 343-1813 Aftercooler As may leak water through the engine induction system and into the engine cylinders. This condition may damage the internal engine components.

Solution

Initial investigations indicate that the leaks are caused by debris lodged in the tubes of the 343-1813 Aftercooler As.

When investigating aftercooler issues, ensure that the engine installation complies with the appropriate Application and Installation guidelines. Check that the flows and pressures are within specifications.

Illustration 1	g06046692

Ensure that the filtration system is within specifications. A sea water strainer (1) must be installed to the inlet side of sea water pump (2). The strainer holes must have a maximum size of 1.6 mm (0.063 inch). The sea water intake pressure must not exceed 1 bar (14.5 psi). Check the water flow rate after installation. Refer to the Technical Marketing Information (TMI). If the recommendations in the Application and Installation guidelines are not followed, the performance of the aftercooler will be affected.

Perform an electrical bonding survey. If the root cause of the issue is not identified, the fault may reoccur. Repairing the engine and replacing the aftercooler may not rectify the root cause of the issue.

Corrosion of the internal components of the engine begins immediately after water ingestion so immediate action must be taken to preserve the engine. If necessary, replace any components that are showing signs of corrosion.

Contact the Dealer Solutions Network (DSN) for assistance when investigating an aftercooler fault.