PSP FOR INSTALLING NEW WATERCOOLED EXHAUST MANIFOLDS ON CERTAIN 3508, 3512, AND 3516 MARINE ENGINES - PS0415 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA, MARINE TEPS
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PSP FOR INSTALLING NEW WATERCOOLED EXHAUST MANIFOLDS ON CERTAIN 3508, 3512, AND 3516 MARINE ENGINES - PS0415 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA, MARINE TEPS
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-56 A-29 AU-33 E-32 O-47 TM-4 1059 PS0415 NOTE: This Program can only be administered after a failure occurs, however, if one bank fails the other bank should be repaired at the same time before failure. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0 " as Part Number, "7755" as Group Number, and "96" as Description Code. This Service Letter replaces the July 28, 1988 Service Letter - PS4206.
Termination Date
March 31, 1991
Problem
The water cooled exhaust manifolds may crack and leak on certain 3508, 3512, and 3516 Marine Engines.
Affected Product
Model Identification Number 3508 96Y1-987 69Z1-508 3512 50Y1-838 66Z1-356 3516 29Z1-913 72Z1-391
Parts Needed
***** 3508 Engines ***** 8 - 7E1754 Gasket-Exhaust Manifold 16 - 4F7389 Seal-Upper Water Lines Group 8 - 8F4994** Seal-Turbo Water Lines Group 4 - 7L4773* Seal-Turbo Water Lines Group 2 - 7M7273 Gasket-Manifold Turbo 2 - 2N0931 Gasket-Expansion Tank 2 - 7N4895 Gasket-Air Shutoff 8 - 8N7640 Gasket-Upper Water Lines Group 4 - 5P5700 Seal Air Lines Group 2 - 1S6595 Gasket-Lines Group Turbo-Oil 2 - 6V2695 Seal O-ring Lines Group-Air 2 - 1W1251 Gasket-Shutoff Group 1 - 9Y8681 Exhaust Manifold (RH) 1 - 9Y8682 Exhaust Manifold (LH) ***** 3512 Engines ***** 12 - 7E1754 Gasket-Exhaust Manifold 24 - 4F7389 Seal-Upper Water Lines Group 6 - 8F4994** Seal-Turbo Water Lines Group 4 - 7L4773* Seal-Turbo Water Lines Group 2 - 7M7273 Gasket-Manifold Turbo 2 - 2N0931 Gasket-Expansion Tank 2 - 7N4895**** Gasket-Air Shutoff 2 - 8N2414***** Gasket-Air Lines Group 12 - 8N7640 Gasket-Upper Water Lines Group 4 - 5P5700 Seal Air Lines Group 2 - 1S6595 Gasket-Lines Group Turbo-Oil 2 - 6V2695 Seal O-ring Lines Group-Air 4 - 6V3917****** Seal Air Lines Group (50Y Only) 2 - 6V5167****** Seal-O-ring Lines Group Air (50Y Only) 2 - 1W1251 Gasket-Shutoff Group 2 - 1W5957*** Gasket-Air Shutoff (50Y Only) 1 - 9Y8683 Exhaust Manifold (RH)1 - 9Y8684 Exhaust Manifold (LH) ***** 3516 Engines ***** 16 - 7E1754 Gasket-Exhaust Manifold 32 - 4F7389 Seal-Upper Water Lines Group 6 - 8F4994 Seal-Turbo Water Lines Group (72Z Only) 4 - 7L4773 Seal-Turbo Water Lines Group (29Z Only) 3 - 2M9780 Seal Lines Group Turbo Oil (29Z Only) 2 - 7M7273 Gasket-Manifold Turbo (72Z Only) 2 - 2N0931 Gasket-Expansion Tank 2 - 7N4895**** Gasket-Air Shutoff (72Z Only) 16 - 8N7640 Gasket-Upper Water Lines Group 4 - 5P5700 Seal Air Lines Group (72Z Only) 2 - 1S6595 Gasket-Lines Group Turbo-Oil (72Z Only) 2 - 6V2695 Seal O-ring Lines Group-Air (72Z Only) 4 - 6V5166 Seal Air Lines Group (29Z Only) 2 - 6V5134 Seal Lines Group Turbo Oil (29Z Only) 2 - 6V5167 Seal-O-ring Lines Group Air (29Z Only) 2 - 1W5505 Gasket-Manifold Turbo (29Z Only) 2 - 1W1251 Gasket-Shutoff Group 2 - 1W5957 Gasket-Air Shutoff (On 72Z****) 1 - 9Y8685 Exhaust Manifold (RH) (72Z Only) 1 - 9Y8686 Exhaust Manifold (LH) (72Z Only) 1 - 9Y8687 Exhaust Manifold (RH) (29Z Only) 1 - 9Y8688 Exhaust Manifold (LH) (29Z Only) The following additional parts will be needed to convert from 4W1695 RH Manifold to the new 9Y8687 RH Manifold on 3516 (29Z) 1 - 7C3604 Pipe - Air Line 1 - 7C3605 Plate - Turbo Oil Lines 2 - 7C9234 Bellow Assembly 2 - 7C9235 Liner - Bellows 1 - 7C9237 Bracket Assembly 1 - 7C9922 Elbow - Exhaust 1 - 7C9924 Elbow - Turbo Oil Drain 1 - 7C9926 Tube - Turbo Oil Drain 1 - 7C9928 Tube Assembly - Turbo Water 1 - 7C9929 Tube Assembly - Right Turbo Oil Supply 3 - 1D4717 Nut 2 - Bracket Assembly 1 - Turbo Oil Tube 3 - 6H1717 Bolt - Bracket Assembly 1 - 0L1143 Bolt - Turbo Oil Tube 1 - 6L1694 Gasket - Turbo Oil Drain Elbow 2 - 9L9132 Washer Bracket Assembly 22 - 5M2894 Washer 16 - Bellows Assembly 2 - Turbo Oil Tube 2 - Air Pipe 2 - Bracket Assembly 2 - 1N4734 Clamp - Turbo Oil Tube 8 - 7N8606 Gasket - Exhaust Manifold 3 - 5P1076 Washer - Bracket Assembly 2 - 0S0509 Bolt - Air Pipe 2 - 0S1571 Bolt - Bracket Assembly 16 - 0S1594 Bolt - Bellows Assembly 2 - 0T0065 Bolt - Oil Drain Tube 2 - 6V5166 Seal - Air Pipe 2 - 6V5167 Seal - Air Pipe 1 - 1W6189 Gasket - Turbo Oil Lines 1 - 1W6190 Gasket - Turbo Oil Lines 4 - 1W7587 Gasket - Bellows 2 - 9Y0195 Retainer - Air Pipe 1 - 9Y0329 Bracket Assembly 1 - 9Y3966 Tube Assembly - Right Turbo Oil Supply * For use with 4MFW and TW81 Turbochargers on the following Affected Product: 96Y618 - 987 66Z154 - 356 69Z255 - 508 29Z1 - 913 50Y540 - 838 ** For use with 4MFW and TW81 Turbochargers on the following Affected Product: 96Y1 - 617 66Z1 - 153 69Z1 - 254 72Z1 - 391 50Y1 - 539 *** For use with 4W0715 Aftercooler Inlet Pipe and 2W5216 Shutoff Group (Attachments) **** For use with 4W0716 Aftercooler Inlet Pipe and 2W7163 or 5N2068 Shutoff Group (Attachments) ***** For use with 7N4898 Aftercooler Inlet Pipe used on 50Y1-519
Action Required
Remove the existing exhaust manifolds and install the new parts.
Service Claim Allowances
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 ***** 3508 Engines ***** 0-4000 100% 12 0 0 0 0 0-24 mo 4001-6000 50% 6 0 0 50% 6 25-36 mo ***** 3512 Engines ***** 0-4000 100% 18 0 0 0 0 0-24 mo 4001-6000 50% 9 0 0 50% 9 25-36 mo ***** 3516 Engines ***** 0-4000 100% 24 0 0 0 0 0-24 mo 4001-6000 50% 12 0 0 50% 12 25-36 mo NOTE: This is a 12 to 24-hour job to rework both banks of the engine.
Parts Disposition
All parts removed (with the exception of cores used for Caterpillar Remanufactured parts) should be rendered useless and scrapped immediately upon completion of the repair.
Caterpillar Information System:
PSP FOR INSTALLING A NEW FUEL SHUTOFF SOLENOID ON CERTAIN 3116 ENGINES USED IN CHEVROLET KODIAK AND GMC TOPKICK TRUCKS - PS4 441 - MAILED US AND CANADA, LIMITED TRUCK TEPS PSP FOR INSTALLING A NEW FUEL SHUTOFF SOLENOID ON CERTAIN 3116 ENGINES USED IN CHEVROLET KODIAK AND GMC TOPKICK TRUCKS - PS4 441 - MAILED US AND CANADA, LIMITED TRUCK TEPS
SERVICE LETTER EXTENSION FOR OCTOBER 5, 1988 SL - PS4260 PSP FOR WIRE ABRASION AND/OR WATER IN THE AIR RATIO LINES GROUP BOO ST LINE ON CERTAIN 3406B ENGINES EQUIPPED WITH PROGRAMMABLE ELECTRONIC ENGINE CONTROL (PEEC) - MAILED US AND CANADA, TRUCK TE SERVICE LETTER EXTENSION FOR OCTOBER 5, 1988 SL - PS4260 PSP FOR WIRE ABRASION AND/OR WATER IN THE AIR RATIO LINES GROUP BOO ST LINE ON CERTAIN 3406B ENGINES EQUIPPED WITH PROGRAMMABLE ELECTRONIC ENGINE CONTROL (PEEC) - MAILED US AND CANADA, TRUCK TE
SERVICE LETTER EXTENSION FOR APRIL 11, 1987 SL - PS0309 - PSP FOR CAMSHAFT FAILURES; 3406B TRUCK ENGINES - MAILED US AND CAN ADA, TRUCK TEPS SERVICE LETTER EXTENSION FOR APRIL 11, 1987 SL - PS0309 - PSP FOR CAMSHAFT FAILURES; 3406B TRUCK ENGINES - MAILED US AND CAN ADA, TRUCK TEPS
NOTIFICATION OF JACOBS REWORK PROGRAM FOR CERTAIN JACOBS MODEL C317 CONTROL MODULES USED ON 3176 ENGINES - MAILED US AND CAN ADA, LIMITED TRUCK TEPS NOTIFICATION OF JACOBS REWORK PROGRAM FOR CERTAIN JACOBS MODEL C317 CONTROL MODULES USED ON 3176 ENGINES - MAILED US AND CAN ADA, LIMITED TRUCK TEPS
PSP FOR INSTALLING DETONATION SENSITIVE TIMING CONTROLS ON CERTAIN 3512 AND 3516 SI ENGINES - PS4400 - MAILED US AND CAN ADA, CACO, COSA PSP FOR INSTALLING DETONATION SENSITIVE TIMING CONTROLS ON CERTAIN 3512 AND 3516 SI ENGINES - PS4400 - MAILED US AND CAN ADA, CACO, COSA
PARTS STOCK ACTION ONLY - 9W9789 SEGMENTS IN PARTS STOCK NEED TO BE INSPECTED FOR MISSING CHAMFER - PI7229 - MAILED US AND CAN ADA, CACO, COFA, BRAZIL, CFEL, COSA PARTS STOCK ACTION ONLY - 9W9789 SEGMENTS IN PARTS STOCK NEED TO BE INSPECTED FOR MISSING CHAMFER - PI7229 - MAILED US AND CAN ADA, CACO, COFA, BRAZIL, CFEL, 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 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
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
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
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
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
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
PSP FOR REPLACING FAILED CYLINDER HEAD GASKETS ON CERTAIN 3406B TRUCK ENGINES - PS0450 - MAILED US AND CANADA, COFA, CFE L, TRUCK TEPS, LIMITED COSA PSP FOR REPLACING FAILED CYLINDER HEAD GASKETS ON CERTAIN 3406B TRUCK ENGINES - PS0450 - MAILED US AND CANADA, COFA, CFE L, TRUCK TEPS, LIMITED COSA
PSP FOR INSTALLING A NEW GOVERNOR DRIVE GEAR ON CERTAIN E110B, E120B, E200B,EL200B,213B,214B,224B,E240B,EL240B EXCAVATORS; CB-434 COMPACTORS; 446 BACKHOE LOADERS; CP-563, CS-563 COMPACTORS; AP-1050 PAVERS; 3114, 3116 ENGINES (COMMERCIAL) - PS4449 - PSP FOR INSTALLING A NEW GOVERNOR DRIVE GEAR ON CERTAIN E110B, E120B, E200B,EL200B,213B,214B,224B,E240B,EL240B EXCAVATORS; CB-434 COMPACTORS; 446 BACKHOE LOADERS; CP-563, CS-563 COMPACTORS; AP-1050 PAVERS; 3114, 3116 ENGINES (COMMERCIAL) - PS4449 -
SERVICE LETTER SUPPLEMENT FOR FEBRUARY 6, 1990 SL - PI3429 - PRIORITY - THE CRANKSHAFT NEEDS TO BE INSPECTED AND REPLACED IF NECESSARY IN CERTAIN 3516 MARINE, GENERATOR SET, INDUSTRIAL SPARK IGNITED, AND LOCOMOTIVE ENGINES; AND 789 TRUCKS - PI3429 - SERVICE LETTER SUPPLEMENT FOR FEBRUARY 6, 1990 SL - PI3429 - PRIORITY - THE CRANKSHAFT NEEDS TO BE INSPECTED AND REPLACED IF NECESSARY IN CERTAIN 3516 MARINE, GENERATOR SET, INDUSTRIAL SPARK IGNITED, AND LOCOMOTIVE ENGINES; AND 789 TRUCKS - PI3429 -
PSP FOR INSTALLING A NEW FAN AND/OR FAN BOLTS ON CERTAIN 3406B GENERATOR SET ENGINES (STANDBY - WITH 9Y0432 450 FRAME SR4 GEN ERATOR) - PS4461 - MAILED US, CANADA, CFEL PSP FOR INSTALLING A NEW FAN AND/OR FAN BOLTS ON CERTAIN 3406B GENERATOR SET ENGINES (STANDBY - WITH 9Y0432 450 FRAME SR4 GEN ERATOR) - PS4461 - MAILED US, CANADA, CFEL
PARTS STOCK ACTION ONLY - CERTAIN 2P5834 OIL FILTER ELEMENTS NEED TO BE REMOVED FROM PARTS STOCK - PI7236 - MAILED US, CAN ADA, CACO COFA, BRAZIL, CFEL, COSA PARTS STOCK ACTION ONLY - CERTAIN 2P5834 OIL FILTER ELEMENTS NEED TO BE REMOVED FROM PARTS STOCK - PI7236 - MAILED US, CAN ADA, CACO COFA, BRAZIL, CFEL, COSA
SERVICE LETTER EXTENSION FOR MAY 17, 1989 SL - PSP FOR TIMING ADVANCE RACE WEAR AND RETAINING RING LOSS ON CERTAIN 3406B TRU CK ENGINES - PS4300 - MAILED US AND CANADA, CACO, COFA, CFEL, TRUCK TEPS, LIMITED COSA SERVICE LETTER EXTENSION FOR MAY 17, 1989 SL - PSP FOR TIMING ADVANCE RACE WEAR AND RETAINING RING LOSS ON CERTAIN 3406B TRU CK ENGINES - PS4300 - MAILED US AND CANADA, CACO, COFA, CFEL, TRUCK TEPS, LIMITED COSA
PRIORITY - PARTS STOCK ACTION NEEDED - NEW GOVERNOR SPEED FILTER NEEDS TO BE INSTALLED ON CERTAIN 3606, 3608, 3612, AND 361 6 GENERATOR SET ENGINES - PI3464 - MAILED US AND CANADA, CACO, COFA, CFEL, LIMITED CFEL PRIORITY - PARTS STOCK ACTION NEEDED - NEW GOVERNOR SPEED FILTER NEEDS TO BE INSTALLED ON CERTAIN 3606, 3608, 3612, AND 361 6 GENERATOR SET ENGINES - PI3464 - MAILED US AND CANADA, CACO, COFA, CFEL, LIMITED CFEL
PSP FOR REPLACING WORN INTAKE VALVE AND/OR VALVE SEATS ON CERTAIN 3508, 3512, AND 3516 MARINE AND GENERATOR SET ENGINES - PS 0446 - MAILED US AND CANADA, CACO, COFA, BRZIL, CFEL, COSA, MARINE TEPS PSP FOR REPLACING WORN INTAKE VALVE AND/OR VALVE SEATS ON CERTAIN 3508, 3512, AND 3516 MARINE AND GENERATOR SET ENGINES - PS 0446 - MAILED US AND CANADA, CACO, COFA, BRZIL, CFEL, COSA, MARINE TEPS
PSP FOR REWORKING THE GOVERNOR ACTUATOR SOLENOID MOUNTING BRACKET AND OIL SUPPLY TUBE ON CERTAIN 3606, 3608, 3612, AND 361 6 ENGINES - PS0449 - MAILED US AND CANADA, CACO, COFA, CFEL, LIMITED COSA PSP FOR REWORKING THE GOVERNOR ACTUATOR SOLENOID MOUNTING BRACKET AND OIL SUPPLY TUBE ON CERTAIN 3606, 3608, 3612, AND 361 6 ENGINES - PS0449 - MAILED US AND CANADA, CACO, COFA, CFEL, LIMITED COSA
PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES - PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES -
PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; 213B, 214B, AND 224B EXC AVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET ENGINES - PS0456 - MAILED COSA PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; 213B, 214B, AND 224B EXC AVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET ENGINES - PS0456 - MAILED COSA
PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES - PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES -