PRODUCT SUPPORT PROGRAM FOR REWORKING AFTERCOOLER ADAPTERS ON CERTAIN 3208 MARINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING AFTERCOOLER ADAPTERS ON CERTAIN 3208 MARINE ENGINES

Usage:

SEBE8593

December 6, 2003
U-333
A-225
D-243
O-275
TM-08

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REWORKING AFTERCOOLER ADAPTERS ON CERTAIN 3208 MARINE ENGINES
1064		PS41437

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 "PS41437" 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, 2005

PROBLEM

The aluminum aftercooler core adapters on certain 3208 marine engines need to be replaced. The adapters on the 425 HP and 435HP Marine Propulsion Engines can corrode and may leak seawater into the inlet manifold.

AFFECTED PRODUCT

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Model	Identification Number
3208	01Z1-32820

PARTS NEEDED

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Qty	Part Number	Description
Adapter replacement only
2	4F8824	SEAL-O-RING
2	5K5959	SEAL-O-RING
2	4P3871	GASKET
2	1451822	ADAPTER
Core replacement
1	7E0429	CORE AS-AFTC
2	7W2329	GASKET

ACTION REQUIRED

Aftercooler adapters should be replaced at or before the regular maintenance interval when other service is being done. Adapters may be difficult to remove and damage to the aftercooler core could result. While the adapters are removed, visually inspect inside the aftercooler housing for signs of seawater ingestion in the engine. It may be necessary in some applications to remove the aftercooler core to do this inspection.

SERVICE CLAIM ALLOWANCES

Adapter Replacement Only

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Product age	Caterpillar		Dealer Suggested		Customer Suggested
Product age	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-24 mos	100%	100%	0	0	0	0
25-36 mos	75%	75%	0	0	25%	1.0
37-48 Mo	50%	50%	0	0	50%	50%
49-60 Mo	25%	25%	0	0	75%	75%
PROPOSED MAXIMUM LABOR ALLOWANCE FOR AFTERCOOLER ADAPTER REPLACEMENT: 1063-010 R&I AFTERCOOLER ADAPTERS 2.5 1000-070 CLEAN ENGINE 0.5 1000-072 PAINT ENGINE 0.5 1000-030 TEST AFTER RPS 0.5

Adapter and Core Replacement

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Product Age		Caterpillar		Dealer Suggested		Customer Suggested
Product Age		Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-24 Mo	100%		100%	0	0	0	0
25-36 Mo	75%		75%	0	0	25%	25%
37-48 Mo	50%		50%	0	0	50%	50%
49-60 Mo	25%		25%	0	0	75%	75%
PROPOSED MAXIMUM LABOR ALLOWANCE FOR AFTERCOOLER ADAPTER REPLACEMENT: 1063-010 R&I AFTERCOOLER ADAPTERS AND CORE 6.5 1000-070 CLEAN ENGINE 0.5 1000-072 PAINT ENGINE 0.5 1000-030 TEST AFTER RPS 0.5