PRODUCT SUPPORT PROGRAM FOR UPDATING CERTAIN C32 ENGINES INSTALLED IN HATTERAS BOATS Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING CERTAIN C32 ENGINES INSTALLED IN HATTERAS BOATS

Usage:

REBE4242-00

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21Oct2008

Z850
Z874
D183

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR UPDATING CERTAIN C32 ENGINES INSTALLED IN HATTERAS BOATS
1380 1379 1221 1405 1326 1154 1000		PS42811

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NOTE:

This Program must 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 "PS42811" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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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TERMINATION DATE

30Apr2010

PROBLEM

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The existing C32 engines installed in Hatteras boats may experience a failure that can result in vessel downtime and customer dissatisfaction.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C32	RNC02180-02184, 2187, 2192, 2194, 2196-2200, 2202, 2204-2207, 2216-2221, 2228-2233, 2242, 2246-2249, 2251, 2260-2261, 2264, 2271, 2274, 2277-2278, 2280-2281, 2283-2287, 2289, 2291-2293, 2296, 2365-2366, 2368, 2374-2377, 2379, 2387-2388, 2390, 2395, 2398, 2404, 2414, 2418, 2420, 2422, 2425-2427, 2431, 2433, 2438, 2442, 2513-2514, 2525, 2534, 2578-2579, 2583-2586, 2588, 2599, 2614-2617, 2622, 2625, 2628, 2630, 2635, 2637, 2697, 2702, 2704-2709, 2711-2712, 2715-2719, 2723-2725, 2727-2730, 2732, 2783-2784, 2796-2797, 2799-2800, 2819-2820, 2822-2823, 2825-2826

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*****Group 2*****
C32	RNC02835-02838

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*****Group 3*****
C32	RNC02884, 2889-2891, 2896, 2898, 2902-2903, 2908, 2934-2935, 2937, 2940-2941, 2950-2953, 2964, 2966, 2979, 2981

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*****Group 4*****
C32	RNC02987, 2989, 3008-3013, 3015, 3032

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*****Group 5*****
C32	RNC03097-03098, 3100

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*******Group 6*******

C32

RXB00184-00191, 200, 204-208, 210, 212-215, 221, 235-242, 261-262, 265-273, 275, 278, 281-282, 316-319, 326-329, 338-339, 345, 2181-2182, 2184-2185, 2192, 2196, 2210, 2213, 2226-2227, 2229, 2231-2233, 2261-2262, 2265-2266, 2268, 2275-2276, 2298-2299, 2301, 2321-2322, 2333, 2335, 2349-2350, 2354-2355, 2357, 2359-2361, 2376, 2378, 2381, 2383-2385, 2388, 2463-2464, 2466, 2471-2472, 2476-2477, 2485, 2507

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*****Group 7*****
C32	RXB03642-03643

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	4P1667	V-BELT SET
2	6V8182	NUT-FULL
1	7X0325	BOLT
2	8T4994	WASHER-HARD
1	8T9392	BOLT
1	0307961	ELBOW
1	1142505	FILM-SERV METER
1	2526498	ROD
1	3005538	WIRE AS-ELEK
1	3015161	TUBE AS
1	3090036	BLOCK
1	3181921	GUARD
2	3297057	BOLT-HEX HEAD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% 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 2*****
1	4P1667	V-BELT SET
2	6V8182	NUT-FULL
1	7X0325	BOLT
2	8T4994	WASHER-HARD
1	8T9392	BOLT
1	0307961	ELBOW
1	1142505	FILM-SERV METER
1	2526498	ROD
1	3005538	WIRE AS-ELEK
1	3015161	TUBE AS
1	3090036	BLOCK
1	3181921	GUARD
2	3297057	BOLT-HEX HEAD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% 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	4P1667	V-BELT SET
2	6V8182	NUT-FULL
1	7X0325	BOLT
2	8T4994	WASHER-HARD
1	8T9392	BOLT
1	1142505	FILM-SERV METER
1	2526498	ROD
1	3005538	WIRE AS-ELEK
1	3090036	BLOCK
1	3181921	GUARD
2	3297057	BOLT-HEX HEAD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% 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 4*****
1	4P1667	V-BELT SET
2	6V8182	NUT-FULL
1	7X0325	BOLT
2	8T4994	WASHER-HARD
1	8T9392	BOLT
1	1142505	FILM-SERV METER
1	2526498	ROD
1	3005538	WIRE AS-ELEK
1	3090036	BLOCK
1	3181921	GUARD
2	3297057	BOLT-HEX HEAD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% 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 5*****
1	4P1667	V-BELT SET
2	6V8182	NUT-FULL
1	7X0325	BOLT
2	8T4994	WASHER-HARD
1	8T9392	BOLT
1	2526498	ROD
1	3090036	BLOCK
1	3181921	GUARD
2	3297057	BOLT-HEX HEAD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% 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 6*****
2	0L1351	BOLT
1	4P1667	V-BELT SET
1	4S1962	CLIP
4	5M2894	WASHER-HARD
2	6D3479	CLIP
1	6V5063	SEAL-O-RING
2	6V8182	NUT-FULL
1	7X0325	BOLT
2	8T4994	WASHER-HARD
1	9G4235	HOSE AS
1	9S4182	PLUG-O-RING
2	9S8752	NUT-FULL
1	0088381	ELBOW
1	0307961	ELBOW
1	0308307	CONNECTOR-FLARED
1	0520572	TEE-SWIVEL
2	1161861	PLATE
1	1470991	HOSE AS
1	2526498	ROD
1	3015161	TUBE AS
1	3090036	BLOCK
1	3181921	GUARD
1	3209903	TUBE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% 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 7*****
1	4P1667	V-BELT SET
1	4S1962	CLIP
1	6V5063	SEAL-O-RING
2	6V8182	NUT-FULL
1	7X0325	BOLT
2	8T4994	WASHER-HARD
1	0088381	ELBOW
1	0308307	CONNECTOR-FLARED
1	2526498	ROD
1	3090036	BLOCK
1	3181921	GUARD
1	3209903	TUBE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% 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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Give careful attention to the groups and the serial numbers to determine the appropriate updates for each engine. Refer to the attached Rework Procedure for details on the following repairs/procedures.

Group 1:
A) Oil Level Gauge Calibration
B) Convert the Vent Lines for the Turbocharger
C) Install the New Turbocharger Oil Line and Water Line
D) Hour Meter Update
E) Heat Exchanger Mounting Bolt Update
F) Alternator Adjusting Rod Update
G) Cylinder Head Spacer Plate Gasket Leak Check
H) Exhaust Support Inspection
I) Sea Trial and Crank Case Blowby Check

Group 2:
B) Convert the Vent Lines for the Turbocharger
C) Install the New Turbocharger Oil Line and Water Line
D) Hour Meter Update
E) Heat Exchanger Mounting Bolt Update
F) Alternator Adjusting Rod Update
G) Cylinder Head Spacer Plate Gasket Leak Check
H) Exhaust Support Inspection
I) Sea Trial and Crank Case Blowby Check

Group 3:
C) Install the New Turbocharger Oil Line and Water Line
D) Hour Meter Update
E) Heat Exchanger Mounting Bolt Update
F) Alternator Adjusting Rod Update
G) Cylinder Head Spacer Plate Gasket Leak Check
H) Exhaust Support Inspection
I) Sea Trial and Crank Case Blowby Check

Group 4:
D) Hour Meter Update
E) Heat Exchanger Mounting Bolt Update
F) Alternator Adjusting Rod Update
G) Cylinder Head Spacer Plate Gasket Leak Check
H) Exhaust Support Inspection
I) Sea Trial and Crank Case Blowby Check

Group 5:
E) Heat Exchanger Mounting Bolt Update
F) Alternator Adjusting Rod Update
G) Cylinder Head Spacer Plate Gasket Leak Check
H) Exhaust Support Inspection
I) Sea Trial and Crank Case Blowby Check

Group 6:
B) Convert the Vent Lines for the Turbocharger
F) Alternator Adjusting Rod Update
J) Turbo Coolant Line Update

Group 7:
F) Alternator Adjusting Rod Update
J) Turbo Coolant Line Update

The repairing dealer must provide an inspection report in SIMSi within the claim story for each of the items identified for that engine. The inspection report must include the results of each check/repair performed. Blowby readings and the other manual readings called out in the sea trail, if performed, need to be included.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-10000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 11.0-hour job for Group 1
Reasonable travel and mileage allowed. When performing rework on two engines in a boat travel can only be claimed to one engine. The other engine serial number must be provided in the claim story on a two engine installation.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-10000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 8.5-hour job for Group 2
Reasonable travel and mileage allowed. When performing rework on two engines in a boat travel can only be claimed to one engine. The other engine serial number must be provided in the claim story on a two engine installation.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
0-10000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 7.5-hour job for Group 3
Reasonable travel and mileage allowed. When performing rework on two engines in a boat travel can only be claimed to one engine. The other engine serial number must be provided in the claim story on a two engine installation.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
0-10000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.5-hour job for Group 4
Reasonable travel and mileage allowed. When performing rework on two engines in a boat travel can only be claimed to one engine. The other engine serial number must be provided in the claim story on a two engine installation.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
0-10000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.0-hour job for Group 5
Reasonable travel and mileage allowed. When performing rework on two engines in a boat travel can only be claimed to one engine. The other engine serial number must be provided in the claim story on a two engine installation.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 6*****
0-10000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 6.5-hour job for Group 6
Reasonable travel and mileage allowed. When performing rework on two engines in a boat travel can only be claimed to one engine. The other engine serial number must be provided in the claim story on a two engine installation.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 7*****
0-10000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 7
Reasonable travel and mileage allowed. When performing rework on two engines in a boat travel can only be claimed to one engine. The other engine serial number must be provided in the claim story on a two engine installation.

PARTS DISPOSITION

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

Rework Procedure

A) Oil Level Gauge Calibration:

Refer to the Operation and Maintenance Manual SEBU7822 (RNC Engines), Engine Oil Level Gauge - Calibrate. Check to see if the engine serial number is called out on service letter PS42484. If PS42484 is applicable to the engine being reworked and has not been completed, perform that service letter rework procedure and claim the repair costs to PS42484.

If the engine serial number is not on PS42484 but is called out in Group 1 serial numbers on this service letter, perform the oil level gauge calibration procedure below and claim the repair costs to this service letter.

NOTE: The engine may be equipped with auxiliary engine oil filters. The extra filters require more engine oil than the standard amounts. Refer to the OEM specifications.

Use the following procedure in order to calibrate and mark the engine oil level gauge.

1. Ensure that the engine is properly aligned and that the engine is in the design trim. The engine must be installed properly in the vessel.

NOTE: If the engine has oil in the crankcase, skip step 2 and proceed to step 3.

2. If there is no oil in the engine, use information in the Operation and Maintenance Manual SEBU7822, "Refill Capacities and Recommendations" in order to select the correct oil for the engine. Add engine oil to the crankcase by using the procedure in the Operation and Maintenance Manual SEBU7822, "Engine Oil and Filter - Change ". Choose the appropriate amount of oil from the following type of sump:

- Standard Oil Sump: Fill the crankcase with 75.7 L (80 qt) of the recommended oil.

Clean the engine oil level gauge and install the engine oil level gauge.

NOTE: If the engine contains oil, perform steps 3 through 7. Skip steps 3 through 7 if you are filling the engine with oil for the first time.

3. Operate the engine until normal operating temperature is achieved. Stop the engine. Drain the engine oil by using the procedure in this Operation and Maintenance Manual, "Engine Oil and Filter - Change ".

4. Replace the engine oil filter by using the procedure in this Operation and Maintenance Manual, "Engine Oil and Filter - Change ".

5. Clean the engine oil level gauge and install the engine oil level gauge.

6. Use the information in Operation and Maintenance Manual, "Refill Capacities and Recommendations" in order to select the correct oil for the engine.

7. Add engine oil to the crankcase by using the procedure in this Operation and Maintenance Manual, "Engine Oil and Filter - Change ". Choose the appropriate amount of oil from the following sump:

- Standard Oil Sump: Fill the crankcase with 75.7 L (80 qt) of the recommended oil.

8. Start the engine. Ensure that the lubrication system and the new engine oil filter are filled. Inspect the lubrication system for leaks.

9. Stop the engine and allow the engine oil to drain into the engine crankcase for approximately twenty minutes.

10. Check the engine oil level. Use a marking tool in order to engrave the "ADD" mark (Y) to the correct location on the gauge assembly.

11. Add 9.5 L (10 qt) of the recommended oil grade and weight of engine oil to the crankcase with a standard sump. Add this amount for both standard sumps and deep sumps. Allow the oil to drain into the sump for approximately 20 minutes.

12. Check the engine oil level. Use a marking tool in order to engrave "FULL" mark (X) onto the correct location on the gauge assembly.

Image1.1.1

B) Convert the Vent Lines for the Turbocharger:

There is an updated water vent line configuration. Refer to Special Instruction REHS3800 - Procedure to Convert the Water Vent Lines for the Turbocharger.

C) Install the New Turbocharger Oil Line and Water Line:

Perform Service Letter PS42541 in conjunction with this program where applicable.

D) Hour Meter Update:

Engine service meter in the start stop box runs constantly.
The 300-5538 Wire that contains a 1 kOhm, 2 Watt resistor can be installed in the Start/Stop control group if the engine is equipped with a 203-4624 Auto Start/Stop Control .

The 300-5538 Wire and the connections for the Start/Stop control harness need to be sealed with heat shrink tubing. Apply heat shrink tubing to the connections of the Start/Stop control harness. The 114-2505 Film can be applied to the service meter in order to provide the correction factor for the correct number of engine hours.

Image1.4.1

Image1.4.2

E) Heat Exchanger Mounting Bolt Update:

Refer to Engine News Article SEBD9549 - Improved Mounting Bolts for the Heat Exchanger on Marine Engines for the rework procedure to update the heat exchanger mounting bolts on affected engines.

F) Alternator Adjusting Rod Update:

For the rework procedure Refer to Engine News Article SEBD9550 - A New Alternator Adjusting Rod is Now Used.

G) Cylinder Head Spacer Plate Gasket Leak Check:

Inspect the cylinder head spacer plate gasket to cylinder block connection for oil leaks. If oil leaks are discovered, ensure the source of the leak is from the spacer plate and not from somewhere else that may be tracking down the head to the spacer plate. Contact your local Caterpillar Service Representative to determine further action if it is confirmed that the spacer plate gasket is leaking.

H) Exhaust Support Inspection:

This procedure is to check for a properly supported boat exhaust system. Remove the four bolts that connect the boats exhaust pipe to the engine turbine housing on each bank of the engine.

The boat exhaust should align with the turbo with very little misalignment in the axial and radial directions. The engine turbochargers are not able to support more than 25 pounds of external load. If misalignment is discovered an adjustment may be required to the stanchion(s) supporting the exhaust piping. You will need to contact the boat manufacturer or an authorized service rep for the manufacturer if exhaust parts are needed.

The exhaust piping supports/stanchions should be mounted to either the engine mounting foot or the marine gear mounting foot and should not be directly mounted to a stringer. If improper mounting is discovered you may need to contact the boat manufacturer or one of their authorized service reps. This service letter only covers the labor required to inspect the exhaust installation. It does not cover any parts or labor required to correct an improperly installed vessel exhaust system and/or piping.

Refer to the Application and Installation Guide for Exhaust Systems, LEBW4970, for additional information on exhaust installation.

I) Sea Trial and Crank Case Blowby Check:

After the updates have been peformed, perform a sea trial if possible. During the sea trial perform a steady state data log using the Performance Set Group in Electronic Technician and record at 240 samples per minute. The manual parameters that should be recorded are: Ambient Air Temp, Inlet Air Temp to each Turbocharger, Exhaust Manifold Temp on each bank, and crankcase blowby.

Measure and record the crank case blowby using the 8T-2700 or equivalent blowby indicator. Refer to Special Instruction SEHS8712 - Using the 8T-2700 Blowby/ Air Flow Indicator.

When measuring blowby on the engine you must disconnect both hoses that connect the valve cover breather to the air cleaner element. Connect the blowby indicator to one of the valve cover breathers at the valve cover. Run the engine under load and record the readings, from one valve cover breather, at 1900 rpm and then at wide open throttle. Once the data is collected multiply the readings by 2 to obtain the blow by for the engine.

The readings should be taken using the cubic feet per hour units. 0.75 cubic feet per hour times horsepower is the acceptable limit for this engine. If the value measured is equal to or greater than 1.5 times cubic feet per horsepower and you are confident the values were measured properly then remove the fuel injectors and perform a boroscope inspection of the cylinder liners and looks for signs of wear. Based on what is discovered additional investigation/repairs may be required. It is preferred to measure the blowby while the engine is operating under load at wide open throttle if this can not be performed than run the engine at high idle and record.

This service letter authorizes the time for the installation/removal of the tooling and the data collection. If additional repairs are required and the engines are outside of the warranty period please consult your Caterpillar Service Representative to determine further required action.

J) Turbo Coolant Line Update:

Drain coolant from engine. Refer to the drain procedure called out in SEBU7908.

Remove the following parts. Refer to Images 1.8.1 and 1.8.2.
1. 202-1967 Tube As
2. 030-8307 Elbow
3. 008-8381 Elbow
4. 6V-5063 O-Ring

Install the following parts. Refer to Image 1.8.3.
1. 320-9903 Tube As
2. 030-8307 Elbow (Replace with new part, do not reuse elbow removed from engine)
3. 008-8381 Elbow (Replace with new part, do not reuse elbow removed from engine)
4. 6V-5063 O-Ring (Replace with new part, do not reuse o-ring removed from engines)
5. 4S-1962 Clip

Fill the engine cooling system with the coolant drained from the engine. Refer to fill procedure called out in SEBU7908. Also refer to the Special Instruction REHS3843 "Procedure for Puring the Cooling System on Marine Applications."