PRODUCT SUPPORT PROGRAM FOR REDUCTION OF AFTERCOOLER CONDENSATE ON CERTAIN C12/3196 MARINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REDUCTION OF AFTERCOOLER CONDENSATE ON CERTAIN C12/3196 MARINE ENGINES

Usage:

REBE3044-00

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10Jan2008

U-21

A-18

D-15

O-17

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REDUCTION OF AFTERCOOLER CONDENSATE ON CERTAIN C12/3196 MARINE ENGINES
1394 1063 1379 3319 1380		PS42599

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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 "PS42599" 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

31Jan2010

PROBLEM

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In marine applications excessive condensation can be produced in the aftercooler assembly especially in colder seawater climates. This condensation can drip directly into the intake ports. The damage that can be caused is corrosion to the valves, valve seats, and cylinder packs leading to shortened engine life.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3196	2XR00433, 506, 570, 577, 645-646, 759, 761, 1003, 1005, 1008, 1561-1562, 2130, 2132-2133, 2538-2539, 3917, 4384-4385, 4581, 4585, 4784-4785, 4868-4869, 5038-5039, 5042-5044, 5046, 5048-5068, 5071-5073, 5076-5085, 5102
C-12	9HP00319, 322-324, 538-540, 543, 708, 710-712, 1110-1113, 1219, 1222, 1396, 1402, 1871, 1873, 2285, 2288
C12	C1Z00280, 962-963

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*****Group 2*****
C12	C1Z01267, 1526

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*****Group 3*****
3196	2XR00541, 571, 914-915, 1013-1014, 1240, 1282, 1337, 1339-1340, 1348, 1350, 1587, 1755, 1765, 1783, 1787, 1819-1820, 1861-1862, 2134-2135, 2181-2182, 2219, 2330-2331, 2445, 2447, 2647, 2849, 3057-3060, 3185-3186, 3188, 3570-3571, 3718, 3751, 3799, 3810, 3912-3913, 3956, 3995, 4117, 4134, 4137, 4392, 4394, 4413, 4419, 4463, 4470, 4498, 4500, 4543-4544, 4713, 4716, 4767, 4799, 4801, 4831-4832, 4995-4996, 5069-5070, 5074-5075
C-12	9HP00125, 238-239, 722, 844, 888, 938, 1353, 1356, 1666, 1671, 2075, 2282, 2350, 2355, 2414, 2476, 2481, 2525, 2539, 2553, 2627, 2696
C12	C1Z00197, 228, 299, 365, 537, 539, 684, 793

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3E7428	PLUG-PIPE
1	5P1259	HOSE
2	6L1651	SEAL-O-RING
2	8T6703	CLAMP-BAND
2	1011640	SLEEVE
1	1782285	TUBE AS
1	3071532	TUBE AS
1	3071533	TUBE AS.
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an inital 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	3E7428	PLUG-PIPE
1	5P1259	HOSE
2	6L1651	SEAL-O-RING
2	8T6703	CLAMP-BAND
2	1011640	SLEEVE
1	1782285	TUBE AS
1	3071533	TUBE AS.
1	3181014	TUBE AS
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an inital 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	3E7428	PLUG-PIPE
1	5P1259	HOSE
2	6L1651	SEAL-O-RING
4	8T6703	CLAMP-BAND
2	1011640	SLEEVE
1	1782285	TUBE AS
1	3071532	TUBE AS
1	3071533	TUBE AS.
1	3197432	HOSE
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an inital 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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Reroute seawater lines from the seawater pump to flow through the heat exchanger and then to the aftercooler. This will increase the seawater temperature to the aftercooler and reduce the amount of condensation formed on the aftercooler core.

NOTE: This rework procedure must only be performed on vessels that operate at very low RPM for extended periods of time, that have the following power ratings, and do not exceed the following sea water temperatures:

- Engines rated at 705 bhp cannot operate in seawater temperatures that exceed 60 Deg F.

- Engines rated at 660 bhp and below cannot operate in sea water temperatures that exceed 68 deg F.

Refer to the attached Rework Procedure.

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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 2.5-hour job for Group 1
Reasonable travel and mileage is covered. Please note the sister engine serial number installed in the boat in the claim story as only one trip will be covered for a pair of engines in a boat.

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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 2.5-hour job for Group 2
Reasonable travel and mileage is covered. Please note the sister engine serial number installed in the boat in the claim story as only one trip will be covered for a pair of engines in a boat.

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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 2.5-hour job for Group 3
Reasonable travel and mileage is covered. Please note the sister engine serial number installed in the boat in the claim story as only one trip will be covered for a pair of engines in a boat.

PARTS DISPOSITION

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

Rework Procedure

NOTE: This rework procedure must only be performed on vessels that operate at very low RPM for extended periods of time, that have the following power ratings, and do not exceed the following sea water temperatures:

- Engines rated at 705 bhp cannot operate in seawater temperatures that exceed 60 Deg F.
- Engines rated at 660 bhp and below cannot operate in sea water temperatures that exceed 68 deg F.

NOTE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTE: Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

1. Enable the derate for high inlet manifold temperature in the ECM and program it to the default setting of 80?C (176?F).

2. Enable the warning for high inlet manifold temperature in the ECM and program it to the default setting of 70?C (158?F).

Refer to Image 1.1.1. for additional details regarding which part numbers are to be reused, replaced and discarded.

Image1.1.1

For steps 3 and 4, refer to Image 1.2.1.

3. Loosen and remove bolts (4), washers (5), hose clamps (3) seawater pump hose (1), and clip (2) which hold tube assembly (13) in place. Store seawater pump hose (1), clip (2) and hose clamps (3), bolts (4), and washers (5) for later use. Discard tube assembly (13).

4. Loosen and remove Bolts (4), Washers (5), Hose Clamps (3), Bulk Hose (6), Tube As. (12), Seal (10), and Sleeve (11). Store Hose Clamps (3), Bolts (4), Washers (5) and Bulk Hose (6) for later use. Discard Seal (10), Sleeve (11), and Tube As. (12).

Image1.2.1

For steps 5, 6, 7, and 8, refer to Image 1.3.1.

5. Attach new Tube As. (8) to Aftercooler and Heat Exchanger using new Seal (10), new Sleeve (11), Reuse Bolts (4), Reuse Washers (5), Reuse Bulk Hose (6) and Reuse Clamps (3).

6. Install New Tube As. (7) while Reusing hose (1), Reuse Bulk Hose (6), Reuse Clamps (3), Reuse Bolt, Washer and Clip (2).

7. Install New Tube Assembly (9) to Aftercooler using New Seal (10), New Sleeve (11), New 1/4" Pipe Plug (15) in Boss on Tube As. 178-2285, Reuse Washers (5), Reuse Bolts (4).

8. If the engine is equipped with a Gilkes Sea Water Pump, install the 318-1014 tube between the Gilkes Sea Water Pump outlet and heat exchanger inlet.

9. If the engine has an Engine Mounted Transmission Oil Cooler, install the 319-7432 hose between the Aftercooler outlet and Oil Cooler inlet. Refer to Image 1.3.2. below.

10. Please note that the formed hose will need to be modified for left hand service engines. Refer to Image 1.3.3. below.