PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE EXPANSION TANK ON CERTAIN C32 MARINE KEEL COOLED ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE EXPANSION TANK ON CERTAIN C32 MARINE KEEL COOLED ENGINES

Usage:

REBE5204-00

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26Jun2009

U-239

A-204

D-206

O-213

TM-21

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE EXPANSION TANK ON CERTAIN C32 MARINE KEEL COOLED ENGINES
1354		PI31669

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31669" 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 "PI31669" 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
31Dec2009	30Jun2010

PROBLEM

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The expansion tank needs to be reworked on certain C32 Marine Engines. The existing expansion tank can crack from excessive loading on the tank welds due to oil canning at resonance of the tank.

AFFECTED PRODUCT

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Model

Identification Number

C32

RND00100, 104-112, 115-122, 125-136, 151-153, 157, 161-162, 167, 169, 172, 174, 176-181, 184-186, 188-191, 198, 200-215, 217, 219-220, 225-226, 230-234, 237-241, 243-244, 246-250, 261-262, 264-265, 272-273, 278-279, 284-285, 298-302, 305-306, 320, 324-325, 335, 337-339

RNE00102, 106-119, 130, 132-133

RNX00109-00110, 112, 115-121, 123-124, 126, 130-134, 140-151, 153, 159-160, 165-167, 171-172, 174-177, 180-181, 183-187, 198, 202-208, 214, 216, 218-219, 221, 223

RNY00100-00111, 113, 115, 118, 120-121, 125, 133, 137, 141, 163, 165, 172, 177-182, 184-188, 192, 194, 199-202, 208-209, 212, 215-219, 223-224, 227, 237, 247, 250, 252, 259, 267-268, 270, 274-275, 277-278, 281, 283, 289, 291, 295, 298, 300-301, 306-307, 310-311, 319, 322-323, 325, 328-329, 336, 344-345, 350-351, 353-354, 359, 368-369, 371-383, 388, 390-391, 393-394, 398, 404-405, 409-411, 415-417, 420-421, 429, 438-439, 449, 452, 455-456, 458-460, 472-473, 486-487, 490, 493, 508, 510, 514, 517, 522-523, 532

PARTS NEEDED

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Qty	Part Number	Description
1	C_CHANNEL	Procure Locally
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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Rework the expansion tank on the affected product.

Refer to the attached Rework Procedure.

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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 4.5-hour job
C Channel must meet requirements called out in the Rework Procedure. C Channel bar stock can be purchased locally. There is a $50 maximum allowance per engine for 785 mm of C Channel bar stock. See Rework Procedure for sizing information. There is a $50 miscellaneous/paint allowance per engine. In the event that there is a After Failure repair an additional 2 hours labor is allowed for welding the existing failed tank prior to installation of C Channel.

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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 REWORKING THE EXPANSION TANK ON CERTAIN MARINE ENGINES

MODELS INVOLVED - C32 Marine Keel Cooled Engines

Dear Caterpillar Product Owner:

The Expansion Tank needs to be reworked on the products listed below. The existing Expansion Tank can crack at the welds. 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 26Jun2009 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 26Jun2009 Service Letter

Rework Procedure

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Prior to performing this procedure refer to "Cooling Systems" A&I Guide media number LEBW4978 to ensure that the customer supplied piping is properly supported. This A&I Guide can be found the web site https://emc.cat.com. Click on the drop down menu and select "Marine" (Image 1.1.1). Select the "Documents" option (circled on Image 1.1.2). Enter LEBW4978 into the "Media Number" field and click on the "Find Media" button (Image 1.1.2 arrows 1 and 2 respectively). Click on the "Download/View" button (Image 1.1.3). Click on the "LEBW4978-04.PDF" link to view the A&I Guide (Image 1.1.4).

Image1.1.1

Image1.1.2

Image1.1.3

Image1.1.4

Weld a C Channel across the center of the front face of the 288-8789 Expansion Tank (Image 1.2.1). The expansion tank is 785 mm wide and is constructed of carbon steel. Follow all guidelines called out in REHS1841 "General Welding Procedures."

Image1.2.1

C Channel should be procured locally and sized according to Image 1.3.1. See Service Claims Allowances for pricing.

Image1.3.1

For engines that have been in service, the Front-Right and Front-Lower seams of the expansion tank need to be re-welded. Remove paint and clean the areas called out in Images 1.4.1 and 1.4.2. Apply a 3 mm continuous weld over each seam.

Image1.4.1

Image1.4.2

To install the C Channel, thoroughly clean the area removing all debris and possible weld contaminations. Center the C Channel on the front face of the tank. The outer edges of the C Channel should be 182.3 mm from the top and bottom edges of the tank, see Imgage 1.5.1.

Image1.5.1

Apply a 3 mm continuous fillet weld on all four edges of the C Channel that contact the surface of the tanks front face (dashed line on Image 1.6.1). The tank wall thickness is only 5 mm, take special care not to blow through the tank when welding. Use a grinder to remove any sharp corners from the C Channel (item 1 on Image 1.6.1). Remove welding slag. Paint the tank area that has be reworked.