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 Caterpillar

U-213
A-136
AU-140
E-92
O-133
1250, 1378  PS4359
NOTE: This Program can be administered either before or after a
failure. In either case the decision whether to apply the
Program is made by the dealer. When reporting the repair, use
"PS4359" as Part Number, "7755" as Group Number, and "96" as
Description Code.
NOTE: When applicable, all updates should be done at the same time.

October 31, 1990

Several changes have been made to 3116 Industrial Engines; and to the 3116
Engines used in E200B, EL200B, 213B, and 214B Excavators. Existing engines
can be updated to reflect these changes.
Update 1 - Several new parts are now used in the fuel injector and valve
mechanism. The new parts will provide improved wear resistance
and service life.
A new wiper seal is used to seal the cylinder head to the governor
connecting tube. The new seal is of a different design and
provides a more positive seal against the governor connecting
tube.
A new governor drive spring is now used. The new spring has
improved strength and increased assembly preload.
Update 2 - A new fuel injector group is now used in 213B Excavator engines.
Some 3116 engines in 213B Excavators have exhibited instability at
low idle. The new injectors provide a more stable low speed idle.
It should be noted the new injectors must NOT be used in the same
engine with the former 9Y2642 Injectors.
Update 3 - Governors now used contain an improved internal governor lever.
The new governors reduce the potential for an internal component
failure. These governors also include the new drive spring
described in update 1.
Update 4 - The oil cooler gasket material has been changed to improve the
sealing of the joint and to improve bolt torque retention on 3116
engines in EL200B and E200B Excavators.

Model Identification Number
***** UPDATE 1 *****
3116 4PG1-398, 400-416, 420, 440, 441-447 450-492
213B 1EJ1-57, 61, 63-67, 72, 74, 76-81, 83, 95, 106
214B 4FC1-26, 30, 32, 33, 35-96, 98, 100, 101, 165
***** UPDATE 2 *****
213B 1EJ1-40, 42-44, 46, 48-50, 52, 59, 61, 83
***** UPDATE 3 *****
3116* 4PG1-398, 400-416, 420, 440-447, 450-461
213B* 1EJ1-40, 42-44, 46, 48-50, 52, 59, 61, 83
214B* 4FC1-26, 30, 32, 33, 35-60, 62-70, 72-74, 82, 90,
101
*The governor's Serial Number must be used to determine whether to replace
the governor. Early governors had a serial number in which the first four
numbers denote the month and year of the governor's manufacture.
Example  03 88 00025
month year
Later governors use an increasing sequence numbering system, using zeros at
the beginning.
Example 000000725
REPLACE all governors with governor serial numbers which begin with a 1187 or
earlier; such as 1187, 1087, 0987, 0887, 0787, 0687, etc.
Example 098700125
DO NOT REPLACE governors with serial numbers which begin with 1287 or later,
or which use the the later governor serial numbering method.
***** UPDATE 4 *****
E200B 6KF1-39, 44, 47-59, 68, 69, 71, 73, 80-85
EL200B 7DF75, 76, 79-81, 83, 90-94, 100, 104, 110, 112, 113, 115, 116,
118, 119, 122-124, 126-130, 133, 143, 144, 146-148, 150,
152, 165, 167-169, 171, 173-175, 178, 184, 188, 190, 193,
197, 210, 211, 226, 229, 246, 247, 249, 251, 253, 258, 260-
262, 267, 269, 270

***** UPDATE 1 *****
1***7C8854 Pin - Clevis (Governor Linkage)
1 - 7E0844 Seal - Wiper (Cylinder Head To Connecting Tube)
1*- 6F6673 Seal - O-Ring (Connecting Tube To Governor Housing)
1*- 1T1068 Seal - O-Ring (Governor to Front Housing)
1***8T1460 Ring - Retaining (Clevis Pin)
6 - 7W3978 Arm Assembly - Injector Rocker
6 - 7W3983 Ring - Retainer (Button)
6 - 7W3985 Arm Assembly - Injector Lifter
3 - 7W9699 Gasket - Side Cover
6 - 9Y1582 Button - Rocker Arm (Fuel Injector)
6 - 9Y4973 Screw - Injection Adjust
1** 9Y5295 Tube - Governor Connecting
1 - 9Y7567 Spring - Governor Drive
1 - 9Y8103 Gasket - Valve Cover
6 - 9Y8205 Rod Assembly - Push (Fuel Injector)
* Use If Required
** Some engines may be equipped with a nylon governor connecting tube. If
so, replace with the following plated metal tube.
*** Use if needed when disconnecting the governor linkage:
***** UPDATE 2 *****
6 - 9Y4982 Injector - Group - Fuel
***** UPDATE 3 *****
1 - 7C6562 Governor Group*
or
7C6867
or
7C6869
or
7W5557
or
7W8178
or
9Y1094
or
9Y2678
or
9Y4025
* Different governor groups may be used on the same engine arrangement. Be
sure to check the governor part number of your engine to make sure it is
replaced by the same part number.
***** UPDATE 4 *****
1 - 7C1161 Gasket - Oil Cooler

***** UPDATE 1 *****
DISASSEMBLY
1. Use a 1U9893 Spanner Wrench and remove the fuel shutoff solenoid.
2. Remove the tube assembly that connects the fuel transfer pump (integral
with governor) to the fuel filter base.
3. Remove the spring clip from the governor connecting tube.
4. Use a 6V0006 Pliers to slide the governor connecting tube into the
intake manifold.
5. Disconnect the governor control linkage clevis from the fuel injection
rack control lever.
6. Remove the governor.
7. Remove the governor connecting tube.
8. Remove the 7C3905 Wiper Seal.
9. Remove the bolt that holds the governor drive cover in position.
10. Remove the governor drive cover.
11. Remove the governor drive spring from the dowels.
12. Remove the valve cover.
NOTE: Before removal, identify the valve rocker arm groups as to their
location in the engine.
13. Remove the valve rocker arm groups.
NOTE: Before removal, identify the intake and exhaust valve push rods
as to their location in the engine.
14. Remove the intake, exhaust and fuel injector push rods.
NOTE: Before removal, identify the side cover assemblies as to their
location on the engine.
15. Remove the side cover assemblies.
NOTE: Before removal, identify the valve lifter arm assemblies as to
their location on the shaft.
16. Remove the lifter shaft assembly from each side cover.
ASSEMBLY
1. Install the new 9Y4973 Injection Adjust Screws in the new 7W3978
Injector Rocker Arm Assemblies.
2. Use the 7W3983 Retainer Ring to install the new 9Y1582 Rocker Arm Button
in each 7W3978 Injector Rocker Arm Assembly.
3. Put the 7W3978 Injector Rocker Arm Assemblies in position on the rocker
arm shaft assemblies.
4. Put the new 7W3985 Injector Lifter Arm Assemblies in position on the
lifter shafts.
5. Install the lifter shaft assemblies on the side covers.
6. Put 8T2998 Lubricant on the camshaft lobes and contact surfaces of the
push rods.
7. Install the side cover gaskets and side cover assemblies.
8. Put the new 9Y7567 Governor Drive Spring in position on the dowels.
NOTE: The governor drive cover can be installed backwards on governors
with S/N's starting with 0787 thru 1087. During assembly, always
put the dowel hole in the cover in alignment with the slot in the
drive gear.
9. Install the governor drive cover.
10. Install the 7E0844 Wiper Seal.
11. Put the governor connecting tube in position.
12. Install the governor.
NOTE: If fuel injector groups were replaced, check Injector
Synchronization and Fuel Setting.
13. Put the intake and exhaust push rods, and the new 9Y8205 Fuel Injector
Push Rod Assemblies in their correct locations.
14 Install the valve rocker arm group in its correct location.
15. Repeat Steps 8 and 9 until all of the push rods and rocker arm groups
are installed.
NOTE: Rotate the crankshaft two complete revolutions to allow the
rocker arms to properly seat on the injectors.
16. If the injector synchronization and fuel setting was not checked use the
1U7305 Insertion Tool to assist in the connection of the governor
control linkage.
17. Perform fuel timing and valve clearance setting adjustments.
18. Install the tube assembly that connects fuel transfer pump (integral
with governor) to the fuel filter base.
19. Use a 1U9893 Spanner Wrench to install the fuel shutoff solenoid.
20. Install the valve cover. Tighten the valve cover bolts in the correct
sequence to a torque of 9 +/- 3 N.m (80 +/- 27 lb in).
***** UPDATE 2 *****
DISASSEMBLY
1. Remove valve cover.
2. Remove rocker arms.
NOTE: Hold the rocker arm stands together when handling. Also identify
the location of each rocker arm group so it is assembled in the
same location.
3. Remove the fuel injector groups from the engine.
ASSEMBLY
1. Install six new 9Y4982 Fuel Injection Groups.
2. Perform injector synchronization adjustments.
3. Install the rocker arms.
4. Check the injector timing and valve lash.
5. Install the valve cover.
***** UPDATE 3 *****
DISASSEMBLY
1. Complete disassembly Steps 1 thru 5 required for Update 1.
2. Remove the governor.
ASSEMBLY
1. Install a 1T1068 O-Ring Seal on the governor housing.
2. Install the governor.
3. Connect the governor control linkage clevis to the fuel injection rack
control lever.
4. Move the governor connecting tube in position and install the spring
clip on the tube.
***** UPDATE 4 *****
DISASSEMBLY
1. Remove the oil filter and oil filter base.
2. Disconnect the Turbocharger oil line.
3. Remove the 15 bolts and oil cooler cover with the cover gasket.
ASSEMBLY
1. Install a new oil cooler cover gasket and install the cover on the oil
cooler.
2. Install the turbocharger oil line.
3. Install the oil filter base and oil filter.

Product Caterpillar Dealer Suggested Customer Suggested
smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
whichever (D/N) (Cost)  (C/L) (Sell)comes
first
***** UPDATE 1 *****
0-3000 100% 4 0 4 0 0
0-24 mo
3001-5000 33 1/3% 2 0 2 50% 4
25-36 mo
***** UPDATE 2 *****
0-3000 100% 3 0 3 0 0
0-24 mo
3001-5000 33 1/3% 1.5 0 1.5 50% 3
25-36 mo
***** UPDATE 3 *****
0-3000 100% .5 0 .5 0 0
0-24 mo
3001-5000 33 1/3% .3 0 .3 50% .4
25-36 mo
***** UPDATE 4 *****
0-3000 100% .5 0 .5 0 0
0-24 mo
3001-5000 33 1/3% .3 0 .3 50% .4
25-36 mo
NOTE: This is a 1 to 8-hour job per update. Repairs performed on 3116
Industrial Engines as per Updates 1 and 3 will be reimbursed for
parts at C/L and labor at Sell.

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