PSP FOR FRONT TIMING GEAR FAILURES ON CERTAIN 3208 TURBOCHARGED AFTERCOOLED MARINE ENGINES USED IN PLEASURE CRAFT APP LICATIONS - PS0405 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA, MARINE TEPS Caterpillar

U-170
A-116
AU-114
E-77
O-105
TM-6
1218, 1288  PS0405
NOTE: This Program can be administered after a failure or before a
failure occurs only as described in the "Action Required"
section. The decision whether to apply the Program is made by
the dealer. Contingent damage to the engine will be allowed, but
must be explained on the claim. When reporting the repair, use
"PS0405" as Part Number, "7755" as Group Number, and "96" as
Description Code.

December 31,1990

There have been some failures of the gear teeth on the engine camshaft gear
assembly and/or fuel injection pump drive gear on later 3208TA Marine
Engines. These are engines used in pleasure craft applications that are
rated at 355 or 375 hp and have an 18.0 deg. BTC fuel injection timing
(static) with no timing advance. (A solid gear is used instead of a timing
advance unit.)
Earlier 355 hp engines had a 15 deg. BTC fuel injection (static) timing with
a 5 deg. automatic timing advance unit and are not included in this program.
Current production engines now have a 15 deg. BTC fuel injection (static)
timing and a 3.5 deg. automatic timing advance unit.

Model Identification Number
3208 TA 1Z3842-3869, 4041-5977, 5979-5981, 5983,
5990-6016, 6019-6024, 6029, 6031, 6032, 6034.
If built to engine arrangements 1W9350 and 7W7500.
NOTE: Some of these engines may have already been reworked. Engines
that have been reworked can be identified by "15.0 deg. BTC Fuel
Timing" stamped on the Engine Information Plate.

1-9N5858 Camshaft (Fuel Pump)
1-7C2856 Gear and Weight As.
1-6V3795 Front Structure Gasket Kit
1-4W5140 Engine Information Plate
1-9L8016 Oil Pan Gasket

If a failure occurs, the new parts should be installed. If an engine in a
multi-engine application fails, the other engine(s) may be reworked at the
same time if they are listed in the Affected Product above.
It will be necessary to remove the engine front housing and the fuel
injection pump to make the repairs. After the new parts have been installed
recalibrate the fuel injection pump. With the installation of the new parts
the fuel timing and performance specification number will change. Stamp the
engine information on the new 4W5140 Plate. The new Fuel Timing and
Performance Specification are shown in the chart. After the information has
been stamped on the new plate, install the new plate over the existing engine
information plate.
Engine Horsepower Performance Specification Fuel Timing
355 hp  0T6441 15.0 BTC
375 hp  0T6428 15.0 BTC

Product Caterpillar Dealer Suggested Customer Suggested
smu Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(C/L) (Sell)  (C/L) (Sell)
0-500 100% 18.5 0 0 0 0
501-1000 100% 0 0 0 0 18.5
NOTE: This is a 18.5-hour job. The labor shown is the time allowed to
install the new parts when the engine is out of the hull.
Additional time will be allowed to disconnect and reconnect the
engine to the driven equipment. This additional time must be
explained in the claim.

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