PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPAIRING CYLINDER HEAD INLET AIR CORROSION ON CERTAIN C18 MARINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPAIRING CYLINDER HEAD INLET AIR CORROSION ON CERTAIN C18 MARINE ENGINES

Usage:

TEBE6037-01

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13Sep2017

(Revised 14Feb2018)

U-471

A-327

D-386

O-390

TM-5

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Before/After	PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPAIRING CYLINDER HEAD INLET AIR CORROSION ON CERTAIN C18 MARINE ENGINES
1100 0644 0700 1222		PS45602

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

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 "PS45602" 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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NOTE:	This Revised Service Letter replaces the 13Sep2017 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

30Sep2019

PROBLEM

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The preservation process at the factory may not have been performed adequately on certain C18 Marine Engines. This can cause the inlet air passage on the cylinder head to have corrosion.

AFFECTED PRODUCT

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Model

Identification Number

C18

JLE05000, 5015, 5017-5018, 5034, 5038, 5044, 5051, 5054-5055, 5061, 5067, 5096, 5098, 5100, 5108-5109, 5115, 5117-5120, 5122, 5125-5126, 5132, 5142-5144, 5146-5149, 5157-5158, 5164-5165, 5168, 5189, 5198-5201, 5212-5214, 5216, 5223, 5230-5233, 5236, 5240, 5242, 5247-5249, 5253, 5258, 5261-5263, 5265, 5268-5272, 5275, 5278, 5280, 5282-5284, 5294-5296, 5299, 5302, 5307, 5309-5310, 5312, 5315, 5317-5319, 5321-5322, 5324, 5326-5328, 5330-5332, 5335-5338, 5342, 5346-5348, 5350-5354, 5356-5358, 5360, 5364-5367, 5372, 5378-5381, 5383-5386, 5388, 5390-5392, 5399-5406, 5408-5410, 5412-5426, 5428-5431, 5433-5437, 5440-5449, 5451-5454, 5458-5459, 5461-5465, 5467-5468, 5470, 5476, 5478-5485, 5487, 5489-5491, 5494-5495, 5497, 5499, 5503-5504, 5508-5512, 5514-5524, 5526-5531, 5533-5534, 5536-5541, 5543-5578, 5580-5581, 5584-5585, 5587-5588, 5590-5594, 5596-5611, 5613, 5615-5624, 5626-5627, 5630-5633, 5636-5638, 5640-5663, 5665-5669, 5671-5694, 5696-5896

PARTS NEEDED

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Qty	Part Number	Description
20	2N2766	LOCKNUT (as required)
24	3E6772	SEAL-WATER (as required)
1	4N0699	GASKET (as required)
2	4P2543	FASTENER (as required)
1	5E8771	SEAL-O-RING (as required)
2	5P0840	SEAL-O-RING (as required)
1	5P5846	SEAL-O-RING (as required)
2	5P7530	SEAL-O-RING (as required)
1	5P8068	SEAL-O-RING (as required)
1	6I2517	GASKET (as required)
2	6J2245	SEAL-O-RING (as required)
4	6V4365	SEAL-O-RING (as required)
1	6V4367	SEAL-O RING (as required)
1	7D7111	SEAL-O-RING (as required)
1	8C3073	SEAL-O-RING (as required)
2	8L2746	SEAL-O-RING (as required)
6	8S9191	BOLT (as required)
6	9L5854	BAND-FILLER (as required)
1	20R3430	HEAD GP-CYL BSC (as required)
12	1061792	STUD-TAPERLOCK (as required)
2	1090072	SEAL-O-RING (as required)
1	1090073	SEAL-O-RING (as required)
1	1090077	SEAL-O-RING (as required)
1	1097411	SEAL-O-RING (as required)
2	1142687	SEAL-O-RING (as required)
2	1144427	SEAL-O-RING (as required)
1	1178801	SEAL-O-RING (as required)
1	1223772	SEAL-O-RING (as required)
1	1250434	SEAL-INTEGRAL (as required)
6	1299452	GASKET-EXH MANF (as required)
1	1422329	SEAL-DRAINBACK (as required)
6	1550809	SEAL-LINER (as required)
12	1552793	SEAL-LINER (as required)
24	1632478	SEAL-VALVE STEM (as required)
1	1674407	SEAL-O-RING (as required)
8	2147568	SEAL-O-RING-STOR (as required)
12	2243983	INSERT-SEAT (as required)
12	2265561	INSERT-VALVE (as required)
1	2271204	GASKET (as required)
2	2385080	SEAL-O-RING-STOR (as required)
1	2385081	SEAL-O-RING-STOR (as required)
6	2465659	RING-PISTON-OIL (as required)
6	2481394	KIT-GASKET-SFI (as required)
2	2492347	FILTER AS-LUBE (as required)
1	3197525	SEAL-PIP (as required)
6	3221126	LINER-CYLINDER (as required)
6	3445153	RING-PISTON (as required)
2	3450412	GASKET (as required)
6	3492568	RING-PISTON-TOP (as required)
2	3571752	GASKET-TURBO (T) (as required)
1	3590908	GASKET-CYL HEAD (as required)
6	3960368	BODY AS-PISTON (as required)
12	4907199	VALVE-INTAKE (as required)
12	4907200	VALVE-EXHAUST (as required)
1	LOCTITE	Loctite 5923 Aviation Sealant (as required)
1	OIL_BULK	45L DEO (as required)
1	VCI_OIL	VCI listed in SEHS9031
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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This letter only applies to engines that have not been started since the engine factory. No action is required for engines that have started since the factory.

For engines not started since the factory, inspect cylinder head intake passage condition through the Inlet Manifold Temperature (IMT) sensor port. Assign a group based on the examination.

Group A) Acceptable rust is present. An example of an acceptable amount of rust is in Image1.

Group B) If rust blisters are present, remove aftercooler and continue inspection for rust in the valve and cylinder areas. An image of rust blisters is in Image2. A small amount of rust is able to be removed using DuBois GX Derust 5575 or other commercially available product. It is important that the removal avoids rust or particles from entering the cylinder.

Group C) If rust blisters require cylinder head removal, follow published reuse and salvage for cylinder head. The head may just need to be disassembled, the rust removed either chemically or mechanically and reassembled. Different levels of severity may also require valves and/or seats or the entire head to be replaced. Utilize Repair vs. Replace methodology for determining the proper course of action.

Group D) If rust has affected piston or liner, salvage or replace affected parts in addition to cylinder head repairs described in Group C.

For all groups: Perform preservation of the inlet air system using SEHS9031 as a reference. It is especially important to spray the VCI into the IMT sensor hole while cranking the engine (SEHS9031 Engine section 7 Note). Attach Product Status Report (ECM download) to claim to be paid.

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Image1

Image2

Image3

Image4

Image5

Image6

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%
0-20 hrs, 0-1 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-hour job
Group A, B, C, D: Reasonable travel and mileage allowed for in hull repairs. (Group A) Additional 2 hours (in hull). (Group B) Additional 6 hours (in shop) and 12 hours (in hull), (Group C) Additional 19 hours R&I head (in shop) plus 5 hours for salvaging head(in shop). Additional 57 hours R&I head (in hull) plus 7.5 hr for salvaging head (in hull). (Group D) Additional 29 hours for replacing 1 PRL (in shop) plus 5 hours for salvaging head(in shop) plus 1.0 hr each additional PRL(in shop). Additional 73 hours (in hull) plus 7.5 hours for salvaging head(in hull) plus 2.0 hr each additional PRL (in hull).