PSP FOR CYLINDER HEAD GASKET FAILURES ON CERTAIN 3306 TRUCK ENGINES - EFFECTIVE OCTOBER 09, 1990 - PS6043 - REPLACES POR TION OF JUNE 20, 1990 SL - PS0453 - INVOLVING 3306 TRUCK ENGINES - MAILED US AND CANADA, COFA, CFEL, TRUCK TEPS, LIMITE D COSA -
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PSP FOR CYLINDER HEAD GASKET FAILURES ON CERTAIN 3306 TRUCK ENGINES - EFFECTIVE OCTOBER 09, 1990 - PS6043 - REPLACES POR TION OF JUNE 20, 1990 SL - PS0453 - INVOLVING 3306 TRUCK ENGINES - MAILED US AND CANADA, COFA, CFEL, TRUCK TEPS, LIMITE D COSA - REVISED 10/91
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.
December 2, 1990 (Revised October 1991) (Effective October 9, 1990) U-239 AU-150 E-145 O-183.2 TT-18 PRODUCT SUPPORT PROGRAM FOR CYLINDER HEAD GASKET FAILURES ON CERTAIN 3306 TRUCK ENGINES 1124 PS6043 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 "PS6043" as Part Number, "7755" as Group Number, and "96" as Description Code. NOTE: This Service Letter Replaces the portion of the June 20, 1990 Service Letter - PS0453 - involving 3306 Truck Engines. NOTE: This Revised Service Letter replaces the December 2, 1990 Service Letter. Changes have been made to the Affected Product, Action Required, Service Claim Allowances, and Parts Disposition.
Termination Date
December 31, 1991
Problem
The 7N7999 Cylinder Head Gasket may fail on certain 3306 Truck Engines allowing compression to leak by the combustion seal either externally or into the cooling system.
Affected Product
Model Identification Number 3306 5KD1-2271 76R1-6584 63Z1-19144
Parts Needed
* 1 - Gasket Kit (Use appropriate gasket kit) **1 - 9L5855 Insert (.030) or 9L5856 Insert (.035) or 9L5857 Insert (.040) or 9L5858 Insert (.045) *1 - 4M2969 Gasket-Oil Pan ***1 - 2P8889 Liner ***3 - 5S6670 Seal ***1 - 2W6134 Band * Part number varies by application. See the parts book microfiche and choose the appropriate gasket kit. Make sure that the gasket kit was updated to include the 7E6167 Cylinder Head Gasket. ** Quantity listed is per cylinder. *** Use as required.
Action Required
After a cylinder head gasket fails, check the fuel settings for probable contribution to the gasket failure. If the engine is found to have been adjusted in excess of specification, this Program cannot be applied. Follow the procedures in the Service Manual to make the necessary repairs using a new 7E6176 Cylinder Head Gasket. The repairs will include lifting the cylinder packs and inspecting for wear/erosion under the liner flanges. Where measurable wear or erosion exists on the cylinder block top deck, make a repair using stainless steel inserts and possibly a new liner. See Special Instruction FMO55228 to install the inserts. Use only stainless steel inserts. If the bottom surface of the cylinder head is damaged, repair by resurfacing or use a Remanufactured cylinder head. The spacer plate should also be inspected for erosion and warpage. Liner projection measurements should be recorded in the dealer service report for reference. When installing the cylinder head, make sure the head bolts and washers are coated with 6V4876 Molykote. Refer to the following articles: Service Magazine, November 19, 1990 "New Head Gasket Used On 3306B Truck Engines"
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested miles/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. whichever comes first 0-300000 100% 100%* 0 0 0 0 0-60 mo 300,001- ** ** 0 0 ** ** 500,000 0-60 mo * See labor breakdowns ** Refer to the following table: Mileage Caterpillar Participation 300,000 - 310,000 100% 310,000 - 320,000 95% 320,000 - 330,000 90% 330,000 - 340,000 85% 340,000 - 350,000 80% 350,000 - 360,000 75% 360,000 - 370,000 70% 370,000 - 380,000 65% 380,000 - 390,000 60% 390,000 - 400,000 55% 400,000 - 410,000 50% 410,000 - 420,000 45% 420,000 - 430,000 40% 430,000 - 440,000 35% 440,000 - 450,000 30% 450,000 - 460,000 25% 460,000 - 470,000 20% 470,000 - 480,000 15% 480,000 - 490,000 10% 490,000 - 500,000 05% NOTE: If repair is performed in conjunction with an in-frame overhaul, apply the service claim allowance toward the cost of the overhaul. ***** Conventional ***** SMCS Code Hours Description 1000-074 0.6 Steam Clean 1000-035 1.0 Troubleshoot to verify complaint 1239-010- -S 19.7 R&I Cylinder Packs (set) 1257-082 0.9 Check Fuel Settings 1216-082-LJ-S 1.2 Check Liner Projection 1000-030 1.0 Test After Repair Add the following if required 1217-012- -F 1.5 Install First Liner Insert 1217-012- -A 0.7 Install Each Additional Liner Insert 1217-012- -S 5.0 Install Set Of Liner Inserts 1119-010-ES-S 1.0 R&I Engine Brake 1100-002 1.8 Transfer Head Components (If Exchange Head Used) ***** Hood ***** SMCS Code Hours Description 1000-074 0.6 Steam Clean 1000-035 1.0 Troubleshoot to verify complaint 1239-010- -S 23.6 R&I Cylinder Packs (set) 1257-082 0.9 Check Fuel Settings 1216-082-LJ-S 1.2 Check Liner Projection 1000-030 1.0 Test After Repair Add the following if required 1217-012- -F 1.5 Install First Liner Insert 1217-012- -A 0.7 Install Each Additional Liner Insert 1217-012- -S 5.0 Install Set Of Liner Inserts 1119-010-ES-S 1.0 R&I Engine Brake 1100-002 1.8 Transfer Head Components (If Exchange Head Used) ***** Short Conventional ***** SMCS Code Hours Description 1000-074 0.6 Steam Clean 1000-035 1.0 Troubleshoot to verify complaint 1239-010- -S 23.9 R&I Cylinder Packs (set) 1257-082 0.9 Check Fuel Settings 1216-082-LJ-S 1.2 Check Liner Projection 1000-030 1.0 Test After Repair Add the following if required 1217-012- -F 1.5 Install First Liner Insert 1217-012- -A 0.7 Install Each Additional Liner Insert 1217-012- -S 5.0 Install Set Of Liner Inserts 1119-010-ES-S 1.0 R&I Engine Brake 1100-002 1.8 Transfer Head Components (If Exchange Head Used) -5- December 2, 1990 (Revised October 1991) ***** Cab Over Engine ***** SMCS Code Hours Description 1000-074 0.6 Steam Clean 1000-035 1.0 Troubleshoot to verify complaint 1239-010- -S 22.1 R&I Cylinder Packs (set) 1257-082 0.9 Check Fuel Settings 1216-082-LJ-S 1.2 Check Liner Projection 1000-030 1.0 Test After Repair Add the following if required 1217-012- -F 1.5 Install First Liner Insert 1217-012- -A 0.7 Install Each Additional Liner Insert 1217-012- -S 5.0 Install Set Of Liner Inserts 1119-010-ES-S 1.0 R&I Engine Brake 1100-002 1.8 Transfer Head Components (If Exchange Head Used)
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Caterpillar Information System:
PSP FOR REPLACING THE CAMSHAFT ON CERTAIN 3306 TRUCK ENGINES - EFFECTIVE OCTOBER 09, 1990 - PS6039 - REPLACES PORTION OF AUG UST 30, 1990 SL - PS0455 - INVOLVING 3306 TRUCK ENGINES - MAILED US AND CANADA, COFA, CFEL, TRUCK TEPS, LIMITED COSA - REVISE PSP FOR REPLACING THE CAMSHAFT ON CERTAIN 3306 TRUCK ENGINES - EFFECTIVE OCTOBER 09, 1990 - PS6039 - REPLACES PORTION OF AUG UST 30, 1990 SL - PS0455 - INVOLVING 3306 TRUCK ENGINES - MAILED US AND CANADA, COFA, CFEL, TRUCK TEPS, LIMITED COSA - REVISE
PARTS STOCK ACTION ONLY - INJECTION PUMP GROUPS FOR USE IN D346 AND D348 ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7 257 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA PARTS STOCK ACTION ONLY - INJECTION PUMP GROUPS FOR USE IN D346 AND D348 ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7 257 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA
PARTS STOCK ACTION ONLY - INJECTOR SLEEVES, CYLINDER HEAD GROUPS , AND CYLINDER HEAD ASSEMBLIES FOR 3176 ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7259 - AMILES US AND CANADA, TRUCK TEPS PARTS STOCK ACTION ONLY - INJECTOR SLEEVES, CYLINDER HEAD GROUPS , AND CYLINDER HEAD ASSEMBLIES FOR 3176 ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7259 - AMILES US AND CANADA, TRUCK TEPS
SERVICE LETTER SUPPLEMENT FOR JUNE 25, 1990 (REVISED 11/90) SL - PS0456 - PSP FOR REPLACING ERODED CYLINDER INJECTOR SLEEVES IN CERTAIN (SEE PAPER COPY FOR APPLICABLE MODELS) - MAILED US AND CANADA, CACO, LIMITED COFA SERVICE LETTER SUPPLEMENT FOR JUNE 25, 1990 (REVISED 11/90) SL - PS0456 - PSP FOR REPLACING ERODED CYLINDER INJECTOR SLEEVES IN CERTAIN (SEE PAPER COPY FOR APPLICABLE MODELS) - MAILED US AND CANADA, CACO, LIMITED COFA
SERVICE LETTER SUPPLEMENT FOR JUNE 12, 1990 SL - PS0446 - PSP FOR REPLACING WORN INTAKE VALVE AND/OR VALVE SEATS ON CERTAIN 350 8, 3512, AND 3516 MARINE AND GENERATOR SET ENGINES - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA, MARINE TEPS SERVICE LETTER SUPPLEMENT FOR JUNE 12, 1990 SL - PS0446 - PSP FOR REPLACING WORN INTAKE VALVE AND/OR VALVE SEATS ON CERTAIN 350 8, 3512, AND 3516 MARINE AND GENERATOR SET ENGINES - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA, MARINE TEPS
Service Letter Supplement Service Letter Supplement
SERVICE LETTER SUPPLEMENT FOR AUGUST 17, 1990 SL - PI3460 - PRIORITY - TRANSMISSION OIL TEMPERATURE GAUGE SENDING UNIT NEE DS TO BE MOVED ON CERTAIN D40D AND D400D ARTICULATED DUMP TRUCKS - MAILED US AND CANADA, CFEL, COSA, LIMITED COFA SERVICE LETTER SUPPLEMENT FOR AUGUST 17, 1990 SL - PI3460 - PRIORITY - TRANSMISSION OIL TEMPERATURE GAUGE SENDING UNIT NEE DS TO BE MOVED ON CERTAIN D40D AND D400D ARTICULATED DUMP TRUCKS - MAILED US AND CANADA, CFEL, COSA, LIMITED COFA
PARTS STOCK ACTION ONLY - CERTAIN WATER PUMPS AND WATER PUMP GASKET KITS FOR 3176 ENGINES NEED TO BE REMOVED FROM PARTS STO CK - PI7254 - MAILED US AND CANADA, TRUCK TEPS PARTS STOCK ACTION ONLY - CERTAIN WATER PUMPS AND WATER PUMP GASKET KITS FOR 3176 ENGINES NEED TO BE REMOVED FROM PARTS STO CK - PI7254 - MAILED US AND CANADA, TRUCK TEPS
PSP FOR INSTALLING STRONGER EXHAUST VALVE PUSH RODS ON CERTAIN 3116 TRUCK ENGINES - PS4530 - MAILED US AND CANADA, LIMITED TRU CK TEPS PSP FOR INSTALLING STRONGER EXHAUST VALVE PUSH RODS ON CERTAIN 3116 TRUCK ENGINES - PS4530 - MAILED US AND CANADA, LIMITED TRU CK TEPS
Product Support Program For Governor Servo Pin Loss On Certain 3304, 3306, 3306B, 3406 And 3406B Engines Product Support Program For Governor Servo Pin Loss On Certain 3304, 3306, 3306B, 3406 And 3406B Engines
PARTS STOCK ACTION ONLY - CERTAIN 9N1547 BEARINGS NEED TO BE REMOVED FROM PARTS STOCK - PI7253 - MAILED US AND CANADA, CACO, CO FA, BRAZIL, CFEL, COSA PARTS STOCK ACTION ONLY - CERTAIN 9N1547 BEARINGS NEED TO BE REMOVED FROM PARTS STOCK - PI7253 - MAILED US AND CANADA, CACO, CO FA, BRAZIL, CFEL, COSA
Product Support Program For Replacing Failed Fuel Injection Nozzles On Certain 3208 Engines Product Support Program For Replacing Failed Fuel Injection Nozzles On Certain 3208 Engines
PSP FOR REPLACING FAILED CYLINDER HEAD GASKETS ON CERTAIN 3406B TRUCK ENGINES - EFFECTIVE OCTOBER 09, 1990 - PS6040 - THI S SL CANCELS AND REPLACES APRIL 12, 1990 (REVISED AUGUST 1990) SL - PS0450 - MAILED US AND CANADA, COFA, CFEL, TRUCK TEPS, LIMIT PSP FOR REPLACING FAILED CYLINDER HEAD GASKETS ON CERTAIN 3406B TRUCK ENGINES - EFFECTIVE OCTOBER 09, 1990 - PS6040 - THI S SL CANCELS AND REPLACES APRIL 12, 1990 (REVISED AUGUST 1990) SL - PS0450 - MAILED US AND CANADA, COFA, CFEL, TRUCK TEPS, LIMIT
PSP FOR REPLACING THE CONNECTING ROD BEARINGS IN CERTAIN 3406B TRUCK ENGINES - EFFECTIVE OCTOBER 09, 1990 - PS6041 - MAILED US AND CANADA, COFA, CFEL, TRUCK TEPS, LIMITED COSA PSP FOR REPLACING THE CONNECTING ROD BEARINGS IN CERTAIN 3406B TRUCK ENGINES - EFFECTIVE OCTOBER 09, 1990 - PS6041 - MAILED US AND CANADA, COFA, CFEL, TRUCK TEPS, LIMITED COSA
PSP FOR TIMING ADVANCE SLIPPAGE ON CERTAIN 3406B TRUCK ENGINES - EFFECTIVE OCTOBER 09, 1990 - PS6042 - THIS SL REPLACES POR TION OF MAY 17, 1990 SL - PS4300 - INVOLVING 3406B TRUCK ENGINES - MAILED US AND CANADA, COFA, CFEL, TRUCK TEPS - LIMITE D COS PSP FOR TIMING ADVANCE SLIPPAGE ON CERTAIN 3406B TRUCK ENGINES - EFFECTIVE OCTOBER 09, 1990 - PS6042 - THIS SL REPLACES POR TION OF MAY 17, 1990 SL - PS4300 - INVOLVING 3406B TRUCK ENGINES - MAILED US AND CANADA, COFA, CFEL, TRUCK TEPS - LIMITE D COS
PSP FOR UPDATING THE GOVERNOR SHUTOFF GROUP ON CERTAIN 3408 AND 3412 GENERATOR SET AND INDUSTRIAL ENGINES EQUIPPED WITH ENE RGIZE TO RUN FUEL SHUTOFF SOLENOIDS - PS4539 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA PSP FOR UPDATING THE GOVERNOR SHUTOFF GROUP ON CERTAIN 3408 AND 3412 GENERATOR SET AND INDUSTRIAL ENGINES EQUIPPED WITH ENE RGIZE TO RUN FUEL SHUTOFF SOLENOIDS - PS4539 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
PSP FOR INSTALLING A NEW 7C7557 VOLTAGE REGULATOR ON CERTAIN 3114, 3116, 3208, 3306, AND 3406 GENERATOR SET ENGINES (BSSB) EQU IPPED WITH A SR4 GENERATOR - PS4538 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA - REVISED 01/91 PSP FOR INSTALLING A NEW 7C7557 VOLTAGE REGULATOR ON CERTAIN 3114, 3116, 3208, 3306, AND 3406 GENERATOR SET ENGINES (BSSB) EQU IPPED WITH A SR4 GENERATOR - PS4538 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA - REVISED 01/91
PRIORITY - SUPPORT NEEDS TO BE ADDED TO INSTRUMENT PANEL FUEL LINE ON CERTAIN 3508, 3512, AND 3516 GENERATOR SET ENGINES EQU IPPED WITH A 4W6887 INSTRUMENT PANEL - PI3492 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA PRIORITY - SUPPORT NEEDS TO BE ADDED TO INSTRUMENT PANEL FUEL LINE ON CERTAIN 3508, 3512, AND 3516 GENERATOR SET ENGINES EQU IPPED WITH A 4W6887 INSTRUMENT PANEL - PI3492 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
Flame Arrestors Need To Be Installed On Certain 3512 And 3516 Spark Ignited Engines To Prevent Inlet Manifold Backfires Flame Arrestors Need To Be Installed On Certain 3512 And 3516 Spark Ignited Engines To Prevent Inlet Manifold Backfires
Product Support Program For Replacing Cracked Cylinder Blocks On Certain 3306B Truck Engines Product Support Program For Replacing Cracked Cylinder Blocks On Certain 3306B Truck Engines
PSP FOR UPDATING THE GOVERNOR SHUTOFF GROUP ON CERTAIN 3406 INDUSTRIAL ENGINES (PCTA) EQUIPPED WITH ENERGIZE TO RUN FUEL SHU TOFF SOLENOIDS - PS4563 - MAILED US AND CANADA, COFA, CFEL, COSA PSP FOR UPDATING THE GOVERNOR SHUTOFF GROUP ON CERTAIN 3406 INDUSTRIAL ENGINES (PCTA) EQUIPPED WITH ENERGIZE TO RUN FUEL SHU TOFF SOLENOIDS - PS4563 - MAILED US AND CANADA, COFA, CFEL, COSA
PSP FOR REPLACING LEAKING EXHAUST GAS INLET HOUSINGS ON CERTAIN 3606, 3608, 3612, AND 3616 ENGINES - PS0457 - MAILED US AND CANADA, CACO, COFA, BRAZIL, LIMITED COSA, LIMITED CFEL PSP FOR REPLACING LEAKING EXHAUST GAS INLET HOUSINGS ON CERTAIN 3606, 3608, 3612, AND 3616 ENGINES - PS0457 - MAILED US AND CANADA, CACO, COFA, BRAZIL, LIMITED COSA, LIMITED CFEL
PRIORITY - PARTS STOCK ACTION NEEDED - A NEW OIL REGULATOR AND OIL REGULATOR HOUSING NEED TO BE INSTALLED ON CERTAIN 3606, 360 8, 3612, AND 3616 ENGINES - PI3486 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA, LIMITED BRAZIL PRIORITY - PARTS STOCK ACTION NEEDED - A NEW OIL REGULATOR AND OIL REGULATOR HOUSING NEED TO BE INSTALLED ON CERTAIN 3606, 360 8, 3612, AND 3616 ENGINES - PI3486 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA, LIMITED BRAZIL
PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE GOVERNORS ON CERTAIN 3116 TRUCK ENGINES PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE GOVERNORS ON CERTAIN 3116 TRUCK ENGINES