PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COOLANT TUBES AND ADDING SPACERS UNDER THE SEA WATER TUBES ON CERTAIN 3508, 3508B, 3512B, 3516B, AND G3516B MARINE ENGINES WITH FRONT MOUNTED HEAT EXCHANGERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COOLANT TUBES AND ADDING SPACERS UNDER THE SEA WATER TUBES ON CERTAIN 3508, 3508B, 3512B, 3516B, AND G3516B MARINE ENGINES WITH FRONT MOUNTED HEAT EXCHANGERS

Usage:

REBE2893-01

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28Jan2008

(Revised 24Jun2008)

U-48

A-40

D-38

O-43

TM-6

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COOLANT TUBES AND ADDING SPACERS UNDER THE SEA WATER TUBES ON CERTAIN 3508, 3508B, 3512B, 3516B, AND G3516B MARINE ENGINES WITH FRONT MOUNTED HEAT EXCHANGERS
1379		PI31439

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31439" 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 "PI31439" 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:	This Revised Service Letter replaces the 28Jan2008 Service Letter. Changes have been made to Service Claims Allowance.

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COMPLETION DATE	TERMINATION DATE
31Jul2008	31Jan2009

PROBLEM

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The existing sea water tubes on certain 3508, 3508B, 3512B, 3516B, and G3516B engines can damage the liners and collars on the heat exchanger causing leaks.

AFFECTED PRODUCT

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Model	Identification Number
3508	95Y01239-01240
3508B	1TW00342 2BM00167-00169, 180-181, 184-187 3DM00350, 467-468, 495-496, 524 7SM00793, 795 S2D00100-00101 S2E00291-00292, 321, 324, 362-363 S2F00102-00119
3512B	1PW00407-00412 2EZ00287-00288, 299-300, 334, 336 2GW00391-00392 4TN00532, 534, 537-538, 551-554, 557-558, 581, 593, 595, 597, 662-665, 688, 690, 697-698, 750, 752-754 7HM00214-00217, 221-222, 225-228, 239-248, 251-254, 259-260, 264-267 8EM00425, 431-432 MKH00206-00207, 224-225, 230-231 S2J00112-00113, 115-116, 119-120, 133-134, 144-145, 157-158, 168-169, 349, 357, 375, 377-379 S2L00101-00108, 119-122, 136-137, 142-145, 154-157, 173, 175, 179-188, 217-219, 221, 283-286, 332, 334-336, 421-422 S2M00102-00141, 147-154, 156, 158-172
3516B	4BW00441-00442, 474, 476-478, 509, 512, 538-543 8KN00457-00459, 462, 551-552, 571-572 9AN00374 PAG00100-00109, 125, 127, 141-142, 157-158, 160-164, 171-172, 188, 192-194, 196-197, 200-201, 210-212, 218, 226-228 S2R00125-00127 S2S00100-00101, 106-107, 110-111, 136-137, 145, 147 S2X00100-00103, 109-110, 151-153, 156, 166-167, 169-170, 204-205, 217, 220, 283-284, 368-369, 490, 493, 495, 740, 742, 749, 795, 798-799 S2Y00100-00105, 109-110
G3516B	ZBC00141-00142, 153

PARTS NEEDED

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Qty	Part Number	Description
4	1369486	LINER
4	1369487	COLLAR
1	1882088	TUBE AS
1	1913053	TUBE AS
2	3189126	SPACER
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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The coolant tubes must replaced and and spacers must be added under the sea water tubes. Refer to 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 8.0-hour job
This is an 8.0 hour job: 2 hours for draining and refilling coolant 2 hours for replacing the tubes and installing the spacers 4 hours to remove and replace damaged liners and collars (this includes removing and replacing the heat exchanger). NOTE: An additional 2.0 hours may be allowed based on installation, (include details in claims story).

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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 REPLACING THE COOLANT TUBES AND ADDING SPACERS UNDER THE SEA WATER TUBES ON CERTAIN 3508, 3508B, 3512B, 3516B, AND G3516B MARINE ENGINES WITH FRONT MOUNTED HEAT EXCHANGERS

MODELS INVOLVED - 3508, 3508B, 3512B, 3516B, G3516B Marine Engines

Dear Caterpillar Product Owner:

The coolant tubes must be replaced and spacers must be added under the sea water tubes on the products listed below. The existing tubes can damage the liners and collars on the heat exchanger causing leaks. 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 28Jan2008 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 28Jan2008 Service Letter

Rework Procedure

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Drain the coolant as required and then remove the sea water and engine coolant tubes from the backside of the front mounted heat exchanger. Inspect the liners and collars for damage. If the liners and collars need replaced, refer to the removal and installation procedure described in Special Instruction REHS2599 (Cleaning the Engine Mounted Heat Exchanger).

NOTE: This service letter does not cover cleaning the engine mounted heat exchanger ar repairing damage to the heat exchanger caused by leaks.

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After damaged liners and collars have been replaced, replace the engine coolant tubes with new tubes and install one spacer between the heat exchanger and each sea water tube.

NOTE: Certain engines were shipped with washers between the heat exchanger and the sea water tubes to keep the tubes from damaging the liners. The liners and collars on these engines will not need to be replaced. The washers should be discarded when the new tubes and spacers are installed.