PRODUCT SUPPORT PROGRAM FOR REWORKING AFTERCOOLER CORES AND ADAPTERS ON CERTAIN 3176 AND 3196 MARINE ENGINES

Usage:

SEBE8487

August 28, 2003
U-233
A-164
D-169
O-192
TM-6

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REWORKING AFTERCOOLER CORES AND ADAPTERS ON CERTAIN 3176 AND 3196 MARINE ENGINES
1063		PS41405

NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS41405" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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.

TERMINATION DATE

December 31, 2003

PROBLEM

Aftercooler Cores and Adapters on certain 3176 and 3196 Marine Engines need to be reworked. The presence of raw water inside the engine can lead to severe engine damage if the problem remains undetected and is not corrected.

AFFECTED PRODUCT

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Model	Identification Number
3176B	9WK1-Up
3176C	6BW1-501
3196	2XR1-4489, 4492-4493, 4503, 4512, 4515-4517, 4522-24, 4529-4536

NOTE: ENGINE MUST SATISFY ONE OF THE CONDITIONS BELOW:

Proactively change the aftercooler cores in engines with 250 hours or less. Engines with 50 hours or less should have priority when scheduling repairs.
Rework new engines in stock at the selling Caterpillar dealer, at the boat OEM, and all new unsold boats at the boat OEM or dealers.
If one engine in a boat qualifies for rework, only rework the sister engine if it also meets the criteria listed below.
Rework engines when S.O.S. shows Na over 50.
Rework engines that have blowby above 750cfh.
Rework engines that have other major repair being done.
Rework engines that have other symptoms of aftercooler failure documented in the claim.
Rework engines in other situations at the discretion of the MPC.

PARTS NEEDED

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Qty	Part Number	Description
1	2215457	Aftercooler Kit**

** KIT CONTAINS THE FOLLOWING PARTS:

1 - 2165147 Aftercooler core
2 ? 1895801 Adapter
1 - 1R0716 Filter Gp ? Oil
2 ? 3P0649 Seal ? Adapter
2 ? 4P3871 Gasket ? Adapter
2 ? 6L1651 Seal ? Sea Water Line
2 ? 1095307 Gasket ? Aftercooler Core
1 ? 1260124 Gasket ? Air Line (4 Bolt Design 3176C/3196)
1 - 1105141 Gasket - Air Line (3 Bolt Design 3176B/early 3176C & 3196)
2 ? 6V3917 Seal ? Air Line to Turbo
3 ? 9X7287 Seal

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product age	Caterpillar		Dealer Suggested		Customer Suggested
Product age	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-60 mos	100%	8.5	0	0	0	0
61-90 mos	100%	4.25	0	0	0	4.25
Above 90 mos	100%	0	0	0	0	8.5
NOTE: This is a 8.5?hr job. NOTE: Premium Freight Charges will also be allowed on engines that are not within the normal warranty period. NOTE: Travel is allowed at 1 man, 1 trip, 1 engine (or at 2 men, 1 trip, 2 engines). Proposed maximum labor allowance for aftercooler replacement: 1063-010 R&I AFTERCOOLER 7.0 1000-070 CLEAN ENGINE 0.5 1000-072 PAINT ENGINE 0.5 1000-030 TEST AFTER RPS 0.5 ONLY IF THE AFTERCOOLER CORE IS THE ONE THE ENGINE WAS ORIGINALLY BUILT WITH: 1063-034 PRESSURE TEST AFTERCOOLER CORE 0.5

Resultant Damage up to 52 hr

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Product age	Caterpillar		Dealer Suggested		Customer Suggested
Product age	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-60 mos	100%	100%	0	0	0	0
61-90 mos	100%	50%	0	0	0	50%
Above 90 mos	100%	0%	0	0	0	100%
NOTE: Travel is allowed at 1 man, 6 trips, 1 engine. NOTE: Resultant damage parts and up to 59 total labor hours (includes aftercooler rework) will be covered by this Service Letter. ONLY IF ENGINE QUALIFIES FOR HEAD AND/OR CYLINDER PACK REPLACEMENT: 1100-002 TRANS COMP 2.0 1000-009 LIFT,BLOCK,LOWER 4.0 1000-076 SEPARATE ENG 7.0 1100-010 R&I CYL HEAD 17.0 1239-010 R&I SIX CYL PACK 15.0 1000-077 CONNECT ENG 7.0 R&I Deck/Hatches to gain access: Outside invoice up to max of $1200 NOTE: If it is necessary to provide safe access to the aftercooler and/or cylinder head, then have the boat yard remove the furniture and carpeting to gain access to the hatches or to remove a section of the deck, and to reassemble the boat after repair is completed. Usual and customary practices should be followed. NOTE: Your Area Caterpillar Service Manager should be contacted for possible alternatives to major repair before major resultant damage repair is begun.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach. (1-Rework Procedure)

Rework Procedure

A) CORE IDENTIFICATION:

Verify that the engine does not already have a 2165147 aftercooler core. 2165147 cores can be identified by the #5147 stamp in the frame of the core that is visible when it is installed on the engine. This can be used to determine if an engine needs to be updated or not. The 2165147 core is contained in the 2215457 aftercooler replacement kit. Do not install the 2215457 kit on engines that already have a 2165147 core. IF A 2165147 CORE IS SUSPECTED OF LEAKING, CALL 309-578-9487 BEFORE REPLACING IT.

Illustration 1

B) REWORK PROCEDURE FOR ENGINES WITH ORIGINAL CORES*:

Check SIMS data to determine if core has been previously replaced. If it is not the original core, proceed to C) below.
Remove the aftercooler core.
Pressure test the core to determine if it has been leaking in operation.* The proper procedure is to pressurize the core to 30 psi. and see if it can hold that pressure for 30 minutes. If the core does not leak, install the 2215457 aftercooler update kit. No further engine repairs beyond a core replacement are authorized for engines with non-leaking original cores. If the core leaks, proceed to Step C.
Change oil and filter.
Clean and paint the engine.
Test the engine after the new core is installed. Enter engine test data in the Sea Trial Data Logger Database.** The web address for Sea Trial Data Logger is listed below: https://engines.cat.com/infocast/frames/marine/techinfo/seatrial/

* An additional 0.5 hour per engine has been added to the repair time only for those engines that are replacing the original core. If the original core does not leak, "No Leak" must be entered in the Part Name field of the warranty claim.

** In order for claim to be paid, STDL must be available in database.

C) REWORK PROCEDURE FOR ENGINES WITH NON-ORIGINAL OR LEAKING CORES:

Remove aftercooler and check inner housing to manifold surface for damage. Housing may also be damaged during forced removal of corroded adapters. Replace as necessary.

Illustration 2 (PITTED AFTERCOOLER HOUSING)

Thoroughly clean salt residue (if any) from the aftercooler housing, and intake manifold passageways to the cylinder head. If one or more of the cylinder head intake ports is badly corroded with scaling rust, as pictured, see ADDITIONAL REPAIRS NEEDED below. Surface rust in the port is OK.

Illustration 3 (SCALING RUST IN CYLINDER HEAD INTAKE PORT)

Inspect/Clean/replace the condensate drain valve and lines as required (Valve should be closed during the 1200-1300rpm acceleration). For front down engines, install on the front of the housing, and on rear down engines, install at the rear of the housing (REGARDLESS OF HOW IT WAS INSTALLED ORIGINALLY).

Illustration 4 (VIEW OF CONDENSATE DRAIN LINE ON REAR)

Check/replace the boost sensor and elbow as required.
Change oil and filter.
Clean and paint the engine.
Test the engine after repairs are made.
Enter engine test data in the Sea Trial Data Logger Database.** The web address for Sea Trial Data Logger is listed below: https://engines.cat.com/infocast/frames/marine/techinfo/seatrial/

** In order for claim to be paid, STDL must be available in database.

D) IF THE ENGINE HAS DOCCUMENTED SLOW ACCELERATION IN 1200-1500RPM RANGE, BUT PULLS FULL LOAD RPM OK, THIS PSP WILL PAY FOR THE FOLLOWING ADDITIONAL PARTS:

ADDITIONAL PARTS NEEDED (If replacement is required)

Aftercooler Drain

2 ? 5P4479 Elbow

1 ? 1112699 Tube AS

1 ? 1337044 Tube AS

1 ? 0520572 Tee

1 ? 7K9197 Elbow

1 ? 4D6432 Locknut (7/16 ? 20 THD)

1 ? 1137696 Adapter

1 ? 1081478 Valve GP

Boost Pressure Sensor

1 ? 2231624 Elbow

1 ? 2183840 Sensor GP ? Pressure

Cylinder Head, Cylinder Packs, and Gaskets

1 ? 10R1526 Remanufactured Cylinder Head

1 ? 2307054 Gasket and Rod Bearing Kit*

*2307054 GASKET AND ROD BEARING KIT CONTAINS THE FOLLOWING PARTS and should only be used on 2XR engines:

6 ? 1161089 Bearing - Connecting Rod

1 ? 1933319 Gasket Kit ? Lower

1 ? 2119979 Gasket Kit ? Cylinder Head

ADDITIONAL REPAIRS NEEDED

Remove the cylinder head and remove and inspect intake valves fed by the rusty scaly port. Carefully inspect valve seats and valve sealing faces with 8S2257 loupe magnification and a good light. Valve insert seats should be smooth and shiny but small pits are ok. Valve sealing face should be smooth (not necessarily shiny). If valves or seats are corroded or guttered, then replace cylinder head with REMAN.