PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE FUEL COOLER ON CERTAIN C15 MARINE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE FUEL COOLER ON CERTAIN C15 MARINE ENGINES

Usage:

SEBE9945-00

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17Aug2006

U-595

A-579

D-568

O-578

TM-507

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE FUEL COOLER ON CERTAIN C15 MARINE ENGINES
1379		PI31136

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31136" 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 "PI31136" 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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COMPLETION DATE	TERMINATION DATE
28Feb2007	31Aug2007

PROBLEM

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Incorrect jacket water routing in the fuel cooler portion of the heat exchanger is causing excessive fuel heating

AFFECTED PRODUCT

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Model	Identification Number
C15	RLA00100-00195, 199-211, 218-253, 255-259, 264-331, 333-536, 538-542

PARTS NEEDED

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Qty	Part Number	Description
1	2944710	EXCH AS-HEAT

ACTION REQUIRED

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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 4.0-hour job

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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 UPDATING THE FUEL COOLER

MODELS INVOLVED - CERTAIN C15 MARINE ENGINES

Dear Caterpillar Product Owner:

A new updated fuel cooler needs to be installed on the engines listed below. Failure to update your engine may result in poor engine performance, and a reduced unit injector life.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 17Aug2006 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 17Aug2006 Service Letter

Rework Procedure

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NOTE: DO NOT REMOVE SHRINK WRAP FROM THE 294-4710 SERVICE KIT UNTIL INSTRUCTED TO DO SO.

COST OF TOOLS IS NOT COVERED UNDER THE SERVICE LETTER

Note: For engines installed in vessels, a short version of the Mounting Bar Tool can be fabricated using a 267-1301 Spacer-Mount and a 134-5573 Stud.

Image1.1.1

NOTICE
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 Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

1. After engine is completely cooled, drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".

2. Disconnect hose assemblies (1) from the heat exchanger.

Image1.4.1

3. Remove bolts (1) and the front spacers from the heat exchanger.

Image1.5.1

4. Install Tooling (A) in the spacers.

5. Remove bolts (2) and bracket (3).

Image1.7.1

6. Loosen bolts for the front frame in a reverse numerical sequence in at least three incremental steps. The plates for the heat exchanger will deflect approximately 30 percent when the bolts for the frame are loosened. Remove front frame.

Image1.8.1

7. Remove the first five plates from the heat exchanger assembly.

Note: DO NOT REMOVE PLATE NO. 6.

8. Slide plate assembly for service kit (294-4710) onto heat exchanger until the kit is approximately 3-4 inches (75-100 mm) from plate no. 6. Plate assembly should be marked for proper orientation.

Note: The gasket on the plate assemblies should face the engine during assembly.

9. Using scissors or a knife, remove the wrap from the plates.

NOTE: Use caution not to damage the seals or to move the seals out of place when removing the wrap.

10. Slide the service kit onto the heat exchanger until the kit contacts plate no. 6.

11. When plates (8) are installed correctly, the edges of the plates will form a honeycomb pattern.

Image1.13.1

12. Position front frame (6) on Tooling (A). Install bolts (7) in front frame (6) and hand tighten the bolts. Tighten the bolts in the numerical sequence that is shown in at least three incremental steps until the front frame is tight against the spacers. Tighten the bolts in equal steps so plates will not bend. The plates for the heat exchanger will compress approximately 30 percent when the bolts for the frame are tightened. Torque bolts to 215 ? 40 N?m (160 ? 30 lb ft).