PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE TORSIONAL VIBRATION DAMPER ASSEMBLY AND FRONT GEAR TRAINS ON CERTAIN C32 ACERT MARINE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE TORSIONAL VIBRATION DAMPER ASSEMBLY AND FRONT GEAR TRAINS ON CERTAIN C32 ACERT MARINE ENGINES

Usage:

SEBE9941-01

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12Jun2006

(Revised 17Jul2006)

U-526

A-518

D-515

O-516

TM-500

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE TORSIONAL VIBRATION DAMPER ASSEMBLY AND FRONT GEAR TRAINS ON CERTAIN C32 ACERT MARINE ENGINES
1205		PI31010

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31010" 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 "PI31010" 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 12 June 2006 Service Letter. Changes have been made to the Parts Needed, Parts Disposition, and Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
31Dec2006	30Jun2007

PROBLEM

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The vibration damper needs to be updated on certain C32 ACERT Marine Engines. The existing damper can lead to front gear train complications.

AFFECTED PRODUCT

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Model	Identification Number
C32	RNC02180-02395, 2398-2427, 2429-2453, 2455-2456, 2458, 2460-2474, 2476, 2478-2482, 2484, 2486, 2488-2489, 2491, 2493, 2496-2499, 2501-2503, 2505-2510, 2512

PARTS NEEDED

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Qty	Part Number	Description
1	1748901	WHEEL-CUTOFF
2	1R1808	FILTER AS.-LUBE
1	2956893	DAMPER KIT
1	2956894	GEAR KIT`

ACTION REQUIRED

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Update engines with new Dual Damper design. Engines with 10 hours or less require only the damper rework.
Engines with more than 10 hours will require the damper rework and a front gear rework.
The front gear rework includes replacement of the crankshaft gear, the idler gear cluster, the camshaft idler gear and the raw water pump gear.

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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 48.0-hour job
NOTE: In Hull Repair - For damper and gear rework: 48 Hours will be allowed. For damper Rework Only: 16 Hours will be allowed NOTE: Out of Hull Repair - For damper and gear rework: 32 Hours will be allowed. For damper rework only: 12 Hours will be allowed

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. For North American Dealers only - engines with over 500 hours please return the torsional vibration damper, crankshaft gear and idler gear cluster to: Caterpillar Service Claims Room 8201 N. University St. Bldg C Dock 22 Peoria, Illinois 61615 Att: Mike J. Smith

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 UPDATING THE TORSIONAL VIBRATION DAMPER ASSEMBLY AND FRONT GEAR TRAINS

MODELS INVOLVED - CERTAIN C32 ACERT MARINE ENGINES
Dear Caterpillar Product Owner:

New torsional vibration dampers need to be installed on the products listed below. 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 17Jul2006 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 17Jul2006 Service Letter

Rework Procedure

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Field Rework for Damper Replacement

Replace existing damper and guard assembly with new style damper and guard assembly.

Rework alternator mounting bracket with spacers and new bolts

Damper Rework Kit Part # 295-6893

Bolt: 1B-2886 Torque to 135 +/- 20 NM

Bolt: 7H-5569 Torque to 215 +/- 40 NM

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Field Rework Procedure for C32 ACERT Marine Engine Gear Replacement

Gear Rework Kit Part # 295-6894

Please consult the RNC C32 ACERT Disassembly and Assembly Manual (RENR8628-00) and the Specification Manual (SENR9772-00).

1. Drain oil

2. Drain coolant

3. Remove oil pan

4. Remove oil lines from oil pump

5. Remove oil pump

6. Remove heat exchanger, belt guard, raw water pump, jacket water pump, alternator belt, and torsional vibration damper

7. Will need to support the engine as the front mounting feet will be removed, ensure rigging will support the weight of the engine. You may need to jack the engine with either a bottle jack or porta-power to install the rigging for supporting the engine.

8. Remove engine front mounting feet

9. Remove engine front cover

Gear Disassembly: Refer to Disassembly and Assembly Manual RENR8628
1. Remove the camshaft dampers
2. Remove the camshaft idler gear and shaft
3. Remove idler gear cluster
4. Remove stub shaft for idler cluster. Very carefully inspect the cylinder block bore where the stub shaft fits to ensure there is no damage to the counter bore. Inspect the stub shaft and ensure there is no damage to the diameter that fits into the block. If the bore is damaged the block must be replaced. If the block and stub are in good order reinstall the stub shaft with NEW bolts and torque to 55 N.M (See Specification Manual SENR9772-00).

Remove Crankshaft Gear:
3? cutting wheel, part # 174-8901, 1 qty
Use Caterpillar grinder 222-3074 or equivalent
Chisel
3 lb slugging hammer or equivalent
Brass Drift or equivalent

SAFETY: Wear gloves, safety glasses and face shield when cutting gear

Protect engine room from debris while cutting the gear
Protect the engine from debris while cutting the gear. Ensure the oil cooler, exhaust manifolds, oil pan, stub shaft bore, camshaft bores are all covered and protected from debris.

Position the crankshaft so the notched part of the gear is accessible. You want to cut between the teeth. Cut down as close to the dowel in the crankshaft as possible without damaging the crankshaft and the block.

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Position the chisel into the cut and hammer until gear ?pops? on the crankshaft. You will be able to remove the gear by hand once it pops.

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Crankshaft Gear Installation:
Thoroughly clean the front of the engine of all debris from the cutting wheel prior to installing the gear. Ensure the crankshaft surface where the gear mounts is clean and not damaged. Inspect the dowel in the crankshaft and ensure it is not damaged.

**DO NOT USE A TORCH TO HEAT THE GEAR**
1. Preheat warming oven to a maximum temperature 2040C (400 0F).
2. Heat crankshaft gear in preheated oven for a minimum of 45 minutes and maximum of 1 hour or until gear temperature reaches 400 deg F. A conical bearing heater can also be used to heat the gear.
3. Use high temperature gloves when handling the hot gear
4. Install gear on the crankshaft with the keyway in alignment with dowel. The timing mark ?V? should face away from the crankshaft.
5. You will have about 1-2 minutes once the gear is removed from the oven to install on the crankshaft before it cools to where it will not fit. If gear does not fit on first try, allow gear to cool completely to room temperature then repeat steps 1 through 3. (NOTE: Reheat may only be performed once!)

6. With gear installed, use a brass drift or equivalent to lightly tap the gear to ensure it is seated all the way on the crankshaft. Hold the gear up against the back lip of the crankshaft until the gear has cooled down enough that it does not move.

The FT2996 jig pictured below can be used to assist with installing the gear onto the crankshaft and holding in place while the gear sets. Again, you do not have much more than 1-2 minutes before the gear cools down.

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NOTE: Make the FT2996 out of 25.4mm (1") square stock. Cut the center bar to 219.55mm and the legs to 95.25mm. Drill 2 - 17.5mm diameter holes in the center at the locations shown. Weld the legs onto the center bar.

7. Check the gear run out on the crank with a set of calipers to ensure it is seated properly and has not cocked. Check the gear at the 12, 3, 6 and 9 o?clock positions. If gear is cocked it must be removed and a new gear must be installed or a gear train failure may occur. A dial indicator can also be used to check the gear run out. Attach the magnetic base to the block and the dial indicator to the face of the gear and turn the engine over 360 degrees. TIR should not exceed 0.015 mm.

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Replace the camshaft idler gear

Replace the raw water pump gear

You do not need to replace the oil pump gear or the jacket water pump gear

Replace the idler gear cluster
Idler Gear Cluster Installation:

Ensure you replace the 5 bolts that secure the idler gear stub shaft to the block.

Torque to 55 N-M or 41lb-ft

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(3) Camshaft drive gear
(4) Idler gear
Install the thrust plate for the idler gear with the oil groove side toward the idler gear assembly. Lubricate the shaft, the bearing bore, and the thrust faces with engine oil.
(5) Crankshaft gear
(6) Oil pump drive gear
(7) Idler shaft
Tighten the five bolts for the idler shaft to the following torque. ... 55 ? 10 N?m (41 ? 7 lb ft)

Follow the assembly instructions called out in the Disassembly and Assembly Manual for the remainder of the assembly

For in hull repairs ensure the engine-gear alignment has been checked and adjusted.

Start and run the engine and check for leaks and proper operation.

At the completion of the sea trial remove the engine oil filters, cut open and inspect filters ONLY IF THE CRANKSHAFT GEAR WAS REPLACED AND CUT OFF THE CRANKSHAFT. Change the engine oil if there is an excessive amount of debris in the filters.