Usage:
Product Support Program For Replacing The Aftercooler Core Housing On Certain 3208 Marine Engines
| SMCS - | 1063 | PS8062 |
December 12, 1993
(Revised June 1995)
U-170
TM-14
A-118
AU-87
B-60
E-133
O-102
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 "PS8062" 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: This Revised Service Letter replaces the December 12, 1993 Service Letter. Changes have been made to the TERMINATION DATE, and Affected Product.
Termination Date
December 31, 1995Problem
Condensation may form on the aftercooler core housing of certain 3208 Marine Engines that operate in water temperatures below 55° F. The condensation may collect in the number six combustion chamber causing a hydraulic lock of the engine. Engines working in climates where the water temperature does not fall below 55° F should not be reworked.
Affected Product
Model & Identification Number
3208 (01Z26960-26962, 01Z26968-26968, 01Z26974-26977, 01Z26983-26983, 01Z26988-26988, 01Z26990-26991, 01Z26994-26995, 01Z26997-26997, 01Z27001-27005, 01Z27007-27009, 01Z27012-27013, 01Z27016-27017, 01Z27023-27023)
Parts Needed
- 1 -1B5174 Plug
- 1 -5D1026 Clamp
- 2 -4F8824 Ring
- 3 -1J8668 Stud
- 2 -5K5959 Seal-O-Ring
- 2 -9L7630 Gasket
- 1 -5M6213 Plug
- 2 -4N4169 Stud
- 2 -4P3871 Gasket
- 110 - 5P0767 Cm-Hose Stock
- 2 -5P8245 Washer-Hard
- 2 -0S1621 Cap Screw
- 2 -1S1476 Clip
- 2 -7W2329 Gasket
- 1 -9X8406 Plug
- 1 -9Y0182 Seal
- 2 -9Y9696 Sleeve
- 1 - 1081478 Valve Group
- 1 - 1096857 Housing Assembly-Aftercooler
- 1 -5D1026 Clamp
Action Required
See attached rework procedure.
Service Claim Allowances
NOTE: This is a 4-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
- (1-Rework Procedure)
Rework Procedure
1. Follow instructions in the Service Manual to remove the sea water aftercooler housing and core assembly.
NOTE: In some installations, it may be easier to remove the aftercooler cover and core assembly before removing the aftercooler housing from the engine. Partially assembling the aftercooler housing on the engine before installing the core assembly may make it easier to install the relatively light housing. The housing must slide forward to engage the flange bolts already installed in the cylinder head where the housing flange is slotted. Sliding the entire housing and core assembly over the inlet manifold gaskets may damage the gaskets. The assembly is heavy and difficult to handle without the use of an overhead lift.
2. After the aftercooler housing is installed, tighten the bolts marked 3 and 4 in Illustration 1 to a torque of 20 ± 7 N·m (15 ± 2 lb ft).
3. Tighten bolts marked 1 through 8 to a torque of 43 ± 7 N·m (32 ± 2 lb ft) following the tightening sequence shown in Illustration 1.
Illustration 1
4. Install the aftercooler housing drain valve and hose as shown in Illustration 2.
Illustration 2
Below is a list of the parts for the rework and the identification of their location on the engine:
