PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AFTERCOOLER ON CERTAIN C4.4 MARINE GENSET ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AFTERCOOLER ON CERTAIN C4.4 MARINE GENSET ENGINES

Usage:

REBE4856-00

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13Apr2009

U-141

A-123

D-119

O-123

TM-10

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AFTERCOOLER ON CERTAIN C4.4 MARINE GENSET ENGINES
1063		PI31653

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31653" 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 "PI31653" 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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NOTE:

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COMPLETION DATE	TERMINATION DATE
31Oct2009	30Apr2010

PROBLEM

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The existing aftercooler can fail on C4.4 Marine Genset engines. If the aftercooler fails, it causes engine down time and potential engine damage due to seawater entry into the engine.

AFFECTED PRODUCT

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Model

Identification Number

C4.4

S1M00163, 166, 169, 174-176, 179-182, 186-187, 192-200, 218-219, 224-225, 233-235, 238, 243-245, 255-259, 262-263, 267-270, 277-283, 287-289, 291, 297, 299-300, 309-311, 318-319, 322-323, 353-361, 364-371, 390-391, 405-407, 410-413, 416-417, 425-428, 436-438, 445-447, 449, 456, 460-466, 468-469, 471-473, 475, 479-481, 485, 489-490, 496, 499-501, 504-505, 507, 517, 526-528, 530-533, 550, 564-565, 570-576, 578-587, 589-599, 614-619, 643-645, 666-667, 674, 692-694, 697-698, 705-706, 712-715, 723-728, 738-739, 748-749, 756, 758-759, 762, 764-765, 774-776, 780-782, 788, 825-826, 834-835, 847, 849, 852, 857-858, 860, 891-894, 898, 902-903, 906-909, 919-920, 929-930, 932-937, 964-965, 979-984, 986-987, 1012-1013, 1016-1017, 1029-1030, 1041-1043, 1068-1070, 1077-1079, 1088-1090, 1106, 1114-1115, 1126-1128, 1131-1134, 1138, 1151-1164, 1168, 1171-1173, 1176-1178, 1185-1190, 1194-1195, 1209, 1211, 1214-1215, 1220-1222, 1226-1227, 1230-1232, 1240, 1242, 1252, 1254, 1257, 1260-1261, 1278, 1284, 1297-1298, 1300-1301, 1306-1307, 1314-1316, 1318-1319, 1331, 1333-1334, 1338, 1344-1345, 1348-1349, 1352, 1372-1373, 1388-1391, 1400-1405, 1407-1408, 1412-1414, 1416-1417, 1429, 1433, 1437-1441, 1447, 1449, 1461, 1469-1470, 1479, 1483-1484, 1486-1487, 1494-1497, 1500, 1502, 1510-1513, 1515-1519, 1521, 1525, 1527, 1529, 1531, 1554, 1556-1557, 1562-1565, 1569, 1576, 1579-1580, 1583, 1589, 1604, 1613, 1615, 1630, 1635, 1657-1658, 1661-1663, 1679-1680, 1683, 1686-1691, 1693-1694, 1697, 1716-1719, 1721, 1723, 1732-1733, 1750, 1752-1753, 1755, 1759-1762, 1777, 1779, 1781-1783, 1790-1796, 1799-1800, 1832-1833, 1837, 1839-1841, 1845-1846, 1848, 1850, 1852, 1855-1856, 1860, 1864-1865, 1867-1868, 1871, 1874, 1876, 1879-1880, 1883, 1886, 1891-1898, 1901-1906, 1912, 1914, 1917, 1921, 1924-1925, 1933, 1939-1942, 1944, 1947-1948, 1953, 1956, 1966-1967, 1969-1970, 1973-1974, 1978, 1989-1990, 1993, 1996-1999, 2002-2003, 2005-2006, 2013, 2033, 2061-2064, 2066-2069, 2075-2079, 2084-2086, 2088-2090, 2119, 2121, 2124, 2128-2129, 2133, 2135-2137, 2141, 2143, 2146, 2148-2157, 2159, 2161-2162, 2164-2165, 2172-2173, 2180, 2184, 2193-2195, 2199, 2202, 2204, 2206, 2208, 2236-2242, 2244-2245, 2255, 2257, 2259, 2261, 2263-2264, 2266, 2268, 2270

PARTS NEEDED

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Qty	Part Number	Description
1	1388436	SEALANT (As Required)
1	1854590	GASKET-LIQUID (As Required)
1	1947227	O-RING
1	2657808	O-RING
1	3431813	AFTERCOOLER AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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1. Inspect the front face of the aftercooler for an "N" mark as shown in Image1.
- If the "N" mark is present, no further rework is necessary.
- If the "N" mark is not present, replace the aftercooler with a new 343-1813 Aftercooler according to Dissassembly and Assembly manual RENR8638.

NOTE: Purchase the appropriate sealant part number for your location. (138-8436 or 185-4590)

NOTE: In order for this rework procedure to be claimed, the engines must have a raw water strainer installed according to the Caterpillar Application and Installation Guidelines for Cooling Systems (LEBW4978).

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Image1

OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.0-hour job
When performing this procedure on a vessel with multiple affected engines, document the other engine serial numbers on the claim. Reasonable travel and mileage allowed.

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PARTS DISPOSITION

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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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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE AFTERCOOLER ON CERTAIN C4.4 MARINE GENSET ENGINES

MODELS INVOLVED - C4.4 Marine Genset Engines

Dear Caterpillar Product Owner:

The aftercooler needs to be inspected and possibly replaced on the C4.4 Marine Gensets listed below. The existing aftercooler can fail. If the aftercooler fails, it causes engine down time and potential engine damage due to seawater entry into the engine. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 13Apr2009 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 13Apr2009 Service Letter