Usage:
Product Support Program For Replacing The Aftercooler Housing Assembly On Certain 375 HP 3208 Marine Engines
| SMCS - | 1063 | PS4718 |
November 23, 1991
(Revised December 1991)
U-234
A-175
AU-156
B-49
E-159
O-176
TM-22
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.
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 "PS4718" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
NOTE: Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.
NOTE: This Revised Service Letter replaces the November 23, 1991 Service Letter. Changes have been made to the housing date codes in the Action Required and Mail Code TM-22 was added.
Termination Date
November 30, 1992Problem
The 2W9994 Aftercooler Housing Assembly on certain 375 HP 3208 Marine engines may have a 6mm (.25 in.) cast rib on the inside of the housing. This rib may interfere with the back of the aftercooler core and may lead to aftercooler core failure over time. Air may also bypass the cooler core due to seal leakage. The engines affected by this program have an identification number less than 01Z24256, with a supplier logo and date code cast in the housing under the air inlet port as shown in the following illustration.
Location of Supplier Logo and Date Code
If the supplier logo shown above is found on the aftercooler housing, and the engine identification number is less than 01Z24256, then replacement is recommended. Engines 01Z24256-Up do not require any rework.
Affected Product
Model & Identification Number
3208 (01Z23565,01Z23574,01Z23594,01Z23599,01Z23623,01Z23625,01Z23629,01Z23637,01Z23643,01Z23646,01Z23648,01Z23650,01Z23652-23657,01Z23659,01Z23663,01Z23666,01Z23669,01Z23671,01Z23673,01Z23676,01Z23679,01Z23681,01Z23684,01Z23687,01Z23691,01Z23694,01Z23697,01Z23699,01Z23700,01Z23702,01Z23712,01Z23714,01Z23719,01Z23722,01Z23724,01Z23727,01Z23729,01Z23738,01Z23747,01Z23752,01Z23759,01Z23762,01Z23764,01Z23767,01Z23769,01Z23771,01Z23774,01Z23776,01Z23778,01Z23782,01Z23784,01Z23786,01Z23788,01Z23795,01Z23802,01Z23806,01Z23809,01Z23811,01Z23813,01Z23815,01Z23818,01Z23820,01Z23822,01Z23827,01Z23829,01Z23846,01Z23859,01Z23863,01Z23869,01Z23875,01Z23884,01Z23886,01Z23892,01Z23897,01Z23900,01Z23906,01Z23909,01Z23913,01Z23915,01Z23917,01Z23920,01Z23922,01Z23924,01Z23926,01Z23927,01Z23930,01Z23932,01Z23935,01Z23938,01Z23940,01Z23943,01Z23946,01Z23948,01Z23951,01Z23954-23956,01Z23958,01Z23959,01Z23964,01Z23967,01Z23970,01Z23973,01Z23975,01Z23977,01Z23979-23981,01Z23984-23986,01Z23988,01Z23991,01Z23993-23995,01Z23997,01Z23999-24001,01Z24004-24006,01Z24008-24012,01Z24014-24022,01Z24024,01Z24025,01Z24027,01Z24029,01Z24031-24038,01Z24041-24045,01Z24047,01Z24049-24051,01Z24053-24057,01Z24059-24062,01Z24064-24067,01Z24069-24072,01Z24074-24088,01Z24090,01Z24094,01Z24098,01Z24102,01Z24104,01Z24108,01Z24109,01Z24111,01Z24112,01Z24114,01Z24116,01Z24118,01Z24120-24127,01Z24129-24132,01Z24135,01Z24144,01Z24149,01Z24152,01Z24156,01Z24162,01Z24167,01Z24172,01Z24175,01Z24177,01Z24183,01Z24185,01Z24187,01Z24192,01Z24193,01Z24196,01Z24198,01Z24201,01Z24203,01Z24206,01Z24209,01Z24219,01Z24220,01Z24222,01Z24224,01Z24234,01Z24236,01Z24242,01Z24244,01Z24255)
Parts Needed
Action Required
Parts Stock
Remove all 2W9994 Housing Assemblies from parts stock that have the supplier logo shown in the illustration and a date code between 01-03-91 and 01-08-91.
Affected Product
1. Inspect the supplier symbol and the date code on the aftercooler housing casting. If the supplier symbol is as shown in the illustration and the date code is 03-01-91 to 08-01-91, proceed with the rework.
2. Paint the new aftercooler housing to match the engine.
3. Follow the procedures in the 3208 Marine Engine Service Manual. Remove the existing aftercooler housing assembly from the engine.
4. Remove the aftercooler core from the aftercooler housing assembly.
5. Carefully remove the Engine Information Plate from the old aftercooler housing.
6. Apply the Engine Information Plate to the new aftercooler housing assembly using 8T9021 Adhesive.
7. Install the aftercooler core in the housing and install the housing assembly on the engine. Be sure to use new 7C4196 Gaskets (Core Flange), 6V5102 O-ring Seal, and new 9L7630 Gaskets (Air Inlet). Follow the proper tightening sequence as described in the Service Manual when tightening the manifold to the cylinder heads.
Service Claim Allowances
Parts Stock
Submit one claim for all 2W9994 Housing Assemblies removed from parts stock.
Affected Product
NOTE: This is a 3-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty bulletin on warranty parts handling.