PSP FOR EXHAUST MANIFOLD LEAKS ON CERTAIN 3608 ENGINES - PS0383 - MAILED US AND CANADA, LIMITED CACO, LIMITED COFA, LIM ITED CFEL, LIMITED COSA
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PSP FOR EXHAUST MANIFOLD LEAKS ON CERTAIN 3608 ENGINES - PS0383 - MAILED US AND CANADA, LIMITED CACO, LIMITED COFA, LIM ITED CFEL, LIMITED COSA
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.
U-198 A-129.1 AU-129.2 E-87.1 O-121.1 1059 PS0383 NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0383" as Part Number, "7755" as Group Number, and "96" as Description Code.
Termination Date
October 31, 1990
Problem
The exhaust manifolds may leak at the joints on certain 3608 Engines. The exhaust leaks can cause complaints and concern due to the smoke and soot in the engine room or area.
Affected Product
Model Identification Number 3608 6MC1-276
Parts Needed
Parts required for all Affected Product 1 - 7E0023 Manifold 112 - 8C8829 Bolt 112 - 8C8825 Locknut 6 - 7E0024 Manifold 14 - 9Y3099 Gasket 7 - 9Y9320 Bellows Assembly 1 - 7E0025 Manifold 2 - 3M7045 Plug 1 - 7E0026 Bellows Assembly 2 - 1W6963 Gasket 16 - 9X2059 Bolt 16 - 7E0031 Washer 16 - 8C8817 Locknut 32 - 5P8245 Washer 32 - 0S1587 Bolt 9 - 5M6213 Plug 9 - 4W8115 Adapter 8 - 1W3305 Gasket 1 - 2N0475 O-ring Seal 1 - 9S6130 Plug 1 - 6V5065 O-ring Seal 1 - 7E0596 Manifold 1 - 2W5023 Gasket 1 - 6V5139 Seal 1 - 6L7817 O-ring Seal 1 - 7E2785 Tube Assembly 1 - 2W4026 Gasket Additional parts required for Affected Product equipped with hardwrap. 1 - 7C2147 Shield Assembly 1 - 7C2148 Shield Assembly 1 - 7E1503 Shield Assembly 1 - 7E1504 Bracket Assembly 1 - 7E1502 Shield Assembly 2 - 8T4179 Bolt 2 - 8T4223 Washer 20 - 9S2087 Screw 62 - 319831 Screw 2 - 7E1501 Shield Assembly Additional parts required for Affected Product equipped with softwrap. 1 - 7E2917 Shield Assembly 1 - 7E2918 Shield Assembly 1 - 7E2919 Shield Assembly 1 - 7E2920 Shield Assembly 1 - 7E2921 Shield Assembly 16 - 319831 Screw 4 - 8T4179 Bolt 4 - 8T4223 Washer 5P1275 Wire
Action Required
Replace the existing exhaust manifold group with the new 9Y3208 Exhaust Manifold Group. Changes to the water lines groups will have to be made to install the new manifolds. Tighten the 32-0S1587 Bolts (manifold to cylinder head) to a torque of 135 +/- 10 N.m (100 +/- 7 lb ft) again after the engine has been run for a minimum of five minutes at rated conditions. The hardwrap or softwrap will have to be replaced after the new manifolds are installed and the tightening procedure has been completed.
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. whichever (C/L) (Sell) (C/L) (Sell) comes first 0-20,000 100% 24 0 0 0 0 0-36 mo NOTE: This is a 24-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. ****** IMAGE: SEBE4150.00001.001 CAPTION:
Caterpillar Information System:
PARTS STOCK ACTION ONLY - THE 7C9699 COMPRESSOR NUT NEEDS TO HAVE THE TORQUE INCREASED ON CERTAIN TURBOCHARGER GROUPS AND CAR TRIDGE GROUPS USED ON 3176 ENGINES - MAILED US AND CANADA, TRUCK TEPS PARTS STOCK ACTION ONLY - THE 7C9699 COMPRESSOR NUT NEEDS TO HAVE THE TORQUE INCREASED ON CERTAIN TURBOCHARGER GROUPS AND CAR TRIDGE GROUPS USED ON 3176 ENGINES - MAILED US AND CANADA, TRUCK TEPS
PARTS STOCK ACTION ONLY - BOLTS AND WASHERS THAT WERE USED TO HOLD THE COUNTERWEIGHT ON THE CRANKSHAFT IN SOME OF THE 3500 SER IES FAMILY OF ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7215 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA, PARTS STOCK ACTION ONLY - BOLTS AND WASHERS THAT WERE USED TO HOLD THE COUNTERWEIGHT ON THE CRANKSHAFT IN SOME OF THE 3500 SER IES FAMILY OF ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7215 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA,
PARTS STOCK ACTION ONLY - CERTAIN ELECTRIC STARTING MOTORS USED ON THE 3100 SERIES FAMILY OF ENGINES NEED TO BE REMOVED FRO M PARTS STOCK - PI7218 - MAILED US AND CANADA PARTS STOCK ACTION ONLY - CERTAIN ELECTRIC STARTING MOTORS USED ON THE 3100 SERIES FAMILY OF ENGINES NEED TO BE REMOVED FRO M PARTS STOCK - PI7218 - MAILED US AND CANADA
PSP FOR INSTALLING A NEW TRANSDUCER MODULE/ELECTRONIC CONTROL MODULE (ECM) WITH AN O-RING SEALING JOINT ON CERTAIN 3176 ENG INES - PS0397 - MAILED US AND CANADA, TRUCK TEPS PSP FOR INSTALLING A NEW TRANSDUCER MODULE/ELECTRONIC CONTROL MODULE (ECM) WITH AN O-RING SEALING JOINT ON CERTAIN 3176 ENG INES - PS0397 - MAILED US AND CANADA, TRUCK TEPS
PSP FOR PREDELIVERY INSPECTION OF 3176 ENGINES - PS9128 - MAILED US AND CANADAC TRUCK TEPS PSP FOR PREDELIVERY INSPECTION OF 3176 ENGINES - PS9128 - MAILED US AND CANADAC TRUCK TEPS
SERVICE LETTER SUPPLEMENT FOR MAY 17, 1989 SL - PS4300 - PSP FOR RETAINING RING LOSS ON CERTAIN 3406B TRUCK ENGINES - MAI LED US AND CANADA, CACO, COFA, CFEL, TRUCK TEPS, LIMITED COSA SERVICE LETTER SUPPLEMENT FOR MAY 17, 1989 SL - PS4300 - PSP FOR RETAINING RING LOSS ON CERTAIN 3406B TRUCK ENGINES - MAI LED US AND CANADA, CACO, COFA, CFEL, TRUCK TEPS, LIMITED COSA
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 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
PARTS STOCK ACTION ONLY:3161 GOVERNOR TOP COVER GASKETS NEED TO BE REMOVED FROM PARTS STOCK - PI7213 - US & CANADA, CACO, COF A, BRAZIL, CFEL, COSA, MARINE TEPS PARTS STOCK ACTION ONLY:3161 GOVERNOR TOP COVER GASKETS NEED TO BE REMOVED FROM PARTS STOCK - PI7213 - US & CANADA, CACO, COF A, BRAZIL, CFEL, COSA, MARINE TEPS
PRIORITY - ON CERTAIN 3176 ENGINES CONTROL GROUP (PERSONALITY MODULE), BOOST LINE CONNECTOR, GROUNDING STUD &/OR PISTON COO LING JETS MAY NEED TO BE REPLACED & ELECTRONIC UNIT EJECTORS MAY NEED TO BE INSPECTED - PI3419 - MAILED US, CANADA TRUCK TEPS PRIORITY - ON CERTAIN 3176 ENGINES CONTROL GROUP (PERSONALITY MODULE), BOOST LINE CONNECTOR, GROUNDING STUD &/OR PISTON COO LING JETS MAY NEED TO BE REPLACED & ELECTRONIC UNIT EJECTORS MAY NEED TO BE INSPECTED - PI3419 - MAILED US, CANADA TRUCK TEPS
PSP FOR INSTALLING A NEW FUEL FILTER HOUSING ON CERTAIN 3606, 3608, 3612, 3616 ENGINES - PS4349 - MAILED US & CANADA, COFA, BRA ZIL, CFEL, LIMITED CACO, LIMITED COSA PSP FOR INSTALLING A NEW FUEL FILTER HOUSING ON CERTAIN 3606, 3608, 3612, 3616 ENGINES - PS4349 - MAILED US & CANADA, COFA, BRA ZIL, CFEL, LIMITED CACO, LIMITED COSA
PRIORITY - RESISTOR NEEDS TO BE INSTALLED ON CERTAIN 3406, 3408 3412 FIRE PUMP ENGINES FOR 3T6352 ALTERNATOR TO WORK COR RECTLY - P13404 - MAILED US & CANADA, COSA, LIMITED COFA PRIORITY - RESISTOR NEEDS TO BE INSTALLED ON CERTAIN 3406, 3408 3412 FIRE PUMP ENGINES FOR 3T6352 ALTERNATOR TO WORK COR RECTLY - P13404 - MAILED US & CANADA, COSA, LIMITED COFA
The Governors Need To Be Reworked On Certain 3412 Engines Equipped With A 9Z5359 Modification (High Output 3412 Custom Marine Engine) The Governors Need To Be Reworked On Certain 3412 Engines Equipped With A 9Z5359 Modification (High Output 3412 Custom Marine Engine)
PSP FOR INSTALLING UNIT INJECTOR ROCKER ARMS, EXHAUST VALVE ROCKER ARMS, AND PISTON CROWNS IN CERTAIN 3176 TRUCK ENGINES - PS4 375 - MAILED US AND CANADA, TRUCK TEPS PSP FOR INSTALLING UNIT INJECTOR ROCKER ARMS, EXHAUST VALVE ROCKER ARMS, AND PISTON CROWNS IN CERTAIN 3176 TRUCK ENGINES - PS4 375 - MAILED US AND CANADA, TRUCK TEPS
PRIORITY - NEW CAMSHAFT SEGMENT NEEDS TO BE INSTALLED IN CERTAIN 3616 ENGINES - PI3433 - MAILED CACO, LIMITED CFEL, LIM ITED COSA PRIORITY - NEW CAMSHAFT SEGMENT NEEDS TO BE INSTALLED IN CERTAIN 3616 ENGINES - PI3433 - MAILED CACO, LIMITED CFEL, LIM ITED COSA
PSP FOR UPDATING CERTAIN 3116 INDUSTRIAL ENGINES; AND THE ENGINES IN CERTAIN E200B, EL200B, 213B, AND 214B EXCAVATORS - PS4 359 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA PSP FOR UPDATING CERTAIN 3116 INDUSTRIAL ENGINES; AND THE ENGINES IN CERTAIN E200B, EL200B, 213B, AND 214B EXCAVATORS - PS4 359 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
PARTS STOCK ACTION ONLY - 9Y1044 SPACER ASSEMBLY USED IN 3176 ENGINES NEEDS TO BE INSPECTED FOR CORRECT THICKNESS - PI7222 - MAI LED US AND CANADA, TRUCK TEPS PARTS STOCK ACTION ONLY - 9Y1044 SPACER ASSEMBLY USED IN 3176 ENGINES NEEDS TO BE INSPECTED FOR CORRECT THICKNESS - PI7222 - MAI LED US AND CANADA, TRUCK TEPS
PARTS STOCK ACTION ONLY - ELECTRONIC UNIT INJECTOR GROUPS USED IN CERTAIN 3176 ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7 221 - MAILED US AND CANADA, TRUCK TEPS PARTS STOCK ACTION ONLY - ELECTRONIC UNIT INJECTOR GROUPS USED IN CERTAIN 3176 ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7 221 - MAILED US AND CANADA, TRUCK TEPS
PSP FOR INSTALLING NEW ROCKER ARM BUTTONS THAT OPERATE WITH INJECTOR TAPPETS THAT ARE NOT FLAT ON CERTAIN 3606, 3608, 3612 AND 3616 ENGINES - PS0417 - MAILED US AND CANADA, CACO, COFA, BRAZIL, LIMITED CFEL, LIMITED COSA PSP FOR INSTALLING NEW ROCKER ARM BUTTONS THAT OPERATE WITH INJECTOR TAPPETS THAT ARE NOT FLAT ON CERTAIN 3606, 3608, 3612 AND 3616 ENGINES - PS0417 - MAILED US AND CANADA, CACO, COFA, BRAZIL, LIMITED CFEL, LIMITED COSA
PSP FOR INSTALLING A NEW HOSE IN THE AIR LINES GROUP OF CERTAIN 3116 TA GENERATOR SET ENGINES - PS4409 - MAILED US AND CAC O, CFEL, COSA, LIMITED COFA PSP FOR INSTALLING A NEW HOSE IN THE AIR LINES GROUP OF CERTAIN 3116 TA GENERATOR SET ENGINES - PS4409 - MAILED US AND CAC O, CFEL, COSA, LIMITED COFA
The 8T0892 Collar Assemblies Used In Various Tool Groups For The 3600 Family Of Engines May Fail The 8T0892 Collar Assemblies Used In Various Tool Groups For The 3600 Family Of Engines May Fail
PRIORITY - NEW WASHERS NEED TO BE INSTALLED ON THE BOLTS THAT HOLD THE COUNTERWEIGHT TO THE CRANKSHAFT IN CERTAIN 777B, 789 TRU CKS; 3508, 3512, 3516 ENGINES - PI3444 - MAILED US AND CANADA, CFEL, COSA, MARINE TEPS, LIMITED CACO, LIMITED COFA PRIORITY - NEW WASHERS NEED TO BE INSTALLED ON THE BOLTS THAT HOLD THE COUNTERWEIGHT TO THE CRANKSHAFT IN CERTAIN 777B, 789 TRU CKS; 3508, 3512, 3516 ENGINES - PI3444 - MAILED US AND CANADA, CFEL, COSA, MARINE TEPS, LIMITED CACO, LIMITED COFA
PSP FOR CRANKSHAFTS IN CERTAIN D10 TRACTORS, D348 ENGINES, 776 TRACTORS, 777 TRUCKS, AND 992 LOADERS - PS0428 - MAILED US AND CAN ADA, CACO, COFA, CFEL, COSA PSP FOR CRANKSHAFTS IN CERTAIN D10 TRACTORS, D348 ENGINES, 776 TRACTORS, 777 TRUCKS, AND 992 LOADERS - PS0428 - MAILED US AND CAN ADA, CACO, COFA, CFEL, COSA
PARTS STOCK ACTION ONLY - NEW CYLINDER HEAD GASKETS USED ON 3408 AND 3412 ENGINES - PI7228 - MAILED US AND CANADA, CACO, COF A, BRAZIL, CFEL, COSA, MARINE TEPS PARTS STOCK ACTION ONLY - NEW CYLINDER HEAD GASKETS USED ON 3408 AND 3412 ENGINES - PI7228 - MAILED US AND CANADA, CACO, COF A, BRAZIL, CFEL, COSA, MARINE TEPS
PRIORITY - THE CRANKSHAFT NEEDS TO BE INSPECTED AND REPLACED IF NECESSARY IN CERTAIN 3516 MARINE, GENERATOR SET, INDUSTRIAL SPA RK IGNITED, AND LOCOMOTIVE ENGINES; AND 789 TRUCKS - PI3429 - MAILED US AND CANADA, CACO, COFA, LIMITED CFEL, LIMITED COSA PRIORITY - THE CRANKSHAFT NEEDS TO BE INSPECTED AND REPLACED IF NECESSARY IN CERTAIN 3516 MARINE, GENERATOR SET, INDUSTRIAL SPA RK IGNITED, AND LOCOMOTIVE ENGINES; AND 789 TRUCKS - PI3429 - MAILED US AND CANADA, CACO, COFA, LIMITED CFEL, LIMITED COSA