3rd Failure Confirmed - 3196 Aftercooler

[Storm]

Picked my aftercooler up from the repair shop today. Shop confirmed the core was leaking from the fins, same as the last two cores. Cat continues to blame the problem on condensation. Piston broke trying to compress seawater in the number five cylinder. Insurance adjuster claims he is currently dealing with two other Cats with an identical problem. Local Cat dealer offered me a new 216-5147 core assembly in exchange for a release from any claims I might have against the company. Of course, that was after they made a point of telling me I had no basis for any claims. Hmmm. I told the dealer the company could keep the bone they were throwing me in the form of another defective 216-5147 core. After three leaky cores and three overhauls in six years, I think it's time they stepped up to the plate and put a new engine in my boat. After all, they knew the last core was defective when they installed it, and they knew what the eventual outcome would be of installing a defective aftercooler on a customer's engine.

I will be sure to post some pics of the $3,300 archaic piece of scrap metal Cat calls an aftercooler. For anyone that hasn't seen one firsthand, they look like a chopped up section of radiator out of a Model T Ford stick welded to a piece of flat plate. Nothing against Fords. I know how sensitive Seapower Frank is about his Ford trucks.

[Big Fish Billy]

What is it about Cats in this Forum...World Cat first now this...seems like basis for another 20,000 view thread...I think I stick with my 454 gassers....

[seapower]

Frank really doesn't care what kind of truck it is, as long as it runs. Once they are paid for they all fall apart, regardless of brand.

[Storm]

Cat claims condensation is the issue with 216-5147 core assemblies. I claim it's electrolysis. Here's the pics. You choose.

[54bullwinkle]

Condensation is FRESH water. Hard to believe fresh water did all that damage. Did your mechanic check for stray current/electrolysis?

P.S. Love my Cats C-32's

Good Luck

[Big Fish Billy]

Cat claims condensation is the issue with 216-5147 core assemblies. I claim it's electrolysis. Here's the pics. You choose.

Boy they sure can make up the fu$king excuses, can't they....

[Captain Michael Buffington]

Boy they sure can make up the fu$king excuses, can't they....

I'd be bent too

Mike

[Big Fish Billy]

I'd be bent too

Mike

I have a buddy with a 3208 in his 35' Duffy, warps a head every year. They just can't seem to fix it for him....

[Storm]

I have a buddy with a 3208 in his 35' Duffy, warps a head every year. They just can't seem to fix it for him....

Cat replaced the cylinder head on my engine in 2003, 2005, and 2006. Head is currently damaged from a piece of stray piston and corrosion from the leaky aftercooler core. Technically, I should be replacing the head again but I'm running out of money for repairs. Heads are $2500 each, aftercoolers are $3,550 with the gasket set. Engine has required about $60,000 in repairs since I purchased it in 2000.

Cat's attorney sent a letter to my attorney stating that Cat stepped up to the plate by replacing an aftercooler in 2002 at my request. The fact is; I didn't request that the aftercooler be replaced. Local Cat service told me my core needed to be replaced. As part of Cat's 2001 3196 and 3176 Marine Engine Aftercooler Support Program, the company pledged to extend the pleasure craft and commercial warranty on 3196 and 3176 aftercoolers to five years from the in-service date - including any subsequent damage caused by a failed core. Under this program, the company had an obligation to replace my core. Under the express limited warranty that came with my engine, Caterpillar also had an obligation to replace any defective parts or componets on my engine. It has been nine years and I'm still waiting for an aftercooler free from defect. Every core on my engine has failed before 3,600 hours.

During the entire episode, Cat has refused to answer my requests for assistance and has never offered any type of apology for my engine troubles. Cat has never put a mechanic on the boat to try and diagnose the problem.

Through my website, I am aware of dozens of other 3196 and C12 owners with the same issues. One family-owned charter business went through seven engines in eight years (total rebuilds and replacements). The most service hours they ever got out of an engine was 1,175 which they describe as "phenomenal." They replaced the engines with Volvos and haven't had any problems since. So there's the cure for the Caterpillar aftercooler problem. Buy something else. Which of course is my plan if I ever can save money again.


Caterpillar customer service is an oxymoron. The company could save money by firing its customer service reps since they don't actually serve any purpose. Maybe the company already has.