PRODUCT SUPPORT PROGRAM FOR INSTALLING VALVES, TURBOCHARGER, EXHAUST MANIFOLD, WATER PUMP AND GASKETS ON CERTAIN BOATS POWERED BY 3126 MARINE ENGINES

Usage:

Caterpillar: Confidential Yellow

PRODUCT SUPPORT PROGRAM FOR INSTALLING VALVES, TURBOCHARGER, EXHAUST MANIFOLD, WATER PUMP AND GASKETS ON CERTAIN BOATS POWERED BY 3126 MARINE ENGINES

SEBE6592-04

August 10, 1998
(Revised November 2001)
U-222
A-205
AU-170
S-102
H-71
O-196
TM-8

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR INSTALLING VALVES, TURBOCHARGER, EXHAUST MANIFOLD, WATER PUMP AND GASKETS ON CERTAIN BOATS POWERED BY 3126 MARINE ENGINES
1052		PS4486

NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4486" 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: 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: Exception To the above note:

This program can only be applied after a valve failure has occured on any engine in Group 1 (8NM1-2199, 6SR1-261). The only exception to this occurs when one engine of a multiple engine boat fails a valve, then the other engine(s) in the boat should be repaired Before failure.

NOTE: This Revised Service Letter replaces the August 10, 1998(Revised October 2000) Service Letter. Changes have been made to the Termination Date.

TERMINATION DATE

November 30, 2002

PROBLEM

Inlet or exhaust valve failure, turbocharger failure, Exhaust manifold failure, or excessive soot build-up on the transom of certain boats, powered by 3126 Marine Engines.

AFFECTED PRODUCT

Model Identification Number

***** Group 1 *****

3126 8NM1-2199
6SR1-261 ***** Group 2 ***** 3126 8NM2200-3196
6SR262-597
4EZ1-31

PARTS NEEDED

Schwitzer Turbo Update

Not required if Schwitzer Turbo has been updated using another Product Support Program.

Not required on 8NM2820-3196, 6SR405-598, 4EZ1-31, 8NM2468, 2639-2640, 2645-2648, 2753-2754, 2835-2836, 2883-2884, 2948-2949, 2973-2976 (470 Hp RIB boat, turbo and manifold updates do not apply)

1 - 0R7255 Turbo (Use 1527460 Production Part no. for stock
engines and new stock boats)
1 - 1347289 Tube Assembly, turbo oil supply
2 - 6V2317 Bolt, tube assembly to turbo
1 - 6V8724 Elbow, tube assembly to base
1 - 1347290 Tube Assembly, turbo oil drain
2 - 6V3940 Bolt, tube assembly to turbo
4 - 9M1974 Washer, turbo inlet/outlet tube assembly bolts
1 - 1493242 Hose, turbo inlet air
1 - 5P1717 Clamp, turbo inlet air

Exhaust Manifold Update

Not required on 8NM2820-3196, 6SR405-598, 4EZ1-31, 8NM2468, 2639-2640, 2645-2648, 2753-2754, 2835-2836, 2883-2884, 2948-2949, 2973-2976 (470 Hp RIB boat, turbo and manifold updates do not apply)

1 - 1515911 Manifold (ductile iron)
4 - 9X8281 Stud, Turbo to Manifold **
1 - 6V1355 Elbow, manifold vent ***
1 - 3J7354 Seal ***
10 - 8T0355 Bolt, manifold to head (Apply Antiseize)***
2 - 8T0644 Bolt, manifold to head (Apply Antiseize)***
12 - 6V5839 Washer, manifold to head***
1 - 1362258 Hose, Sea water to Riser
1 - 1362259 Bracket As. Riser Support
1 - 1265882 Hose turbo outlet

** Not required on 8NM2665-2819 or 6S275-404
*** Not required on 8NM2210-2819 or 6SR207-404

Engine Valve, Water Pump, And Gasket Update

6 - 1577125 Intake Valve
6 - 1577126 Exhaust Valve
6 - 1309004 Intake valve insert
1 - 1593138 Pump Assembly, J.W.
1 - 4W7592 Gasket, Water pump
1 - 1169924 Oil Filter
1 - 1192940 Gasket, Valve Cover
1 - 1443450 Gasket, Cylinder head
12 - 1193036 Seals, Valve Stem
1 - 1136250 Gasket, Intake manifold
2 - 7C1152 Gasket, Aftercooler
1 - 7C1159 Gasket, Fuel filter base
1 - 2W7212 Gasket, Regulator housing
1 - 4P7704 Gasket, Turbo to manifold
3 - 1136200 Gasket, manifold to head
1 - 1S7057 Gasket, Tube as to turbo
1 - 7W2398 Gasket, Tube as to turbo
1 - 6V8397 Seal, Elbow
1 - 3J1907 Seal, Elbow
1 - 9M4849 Seal, Tube as to block elbow
1 - 7C7613 Gasket, Turbo to exh riser
1 - 7C1159 Breather Gasket
2 - 8T0280 O-ring
1 - 4F7391 O-ring, oil drain
6 - 1148718 O-ring, Injector top seal
1 - 6F6673 O-ring, Governor
1 - 7E0844 O-ring Governor
3 - 3D2824 O-ring, water line
1 - 1271552 Bracket, to heat exchanger*
1 - 5P9297 Clip, fuel line to bracket*
1 - 8T4189 Bolt (M8)*
1 - 8T4224 Washer*
1 - 5C7261 Nut (M8)*
1 - 7F8267 Seal, Water Pump Mtg.
1 - 2M4453 Seal, Water Pump Mtg.

Required only for 8NM1-1975 with RH service fuel filter

WATER-COOLED EXHAUST RISER UPDATE

Not required on 8NM1975-3196, 6SR1-597, 4EZ1-31

1 - 1369081 Exhaust Riser
4 - 6V1820 Bolt, Riser to Turbo
4 - 3E4353 Washer, Riser to Turbo

DRY EXHAUST ELBOW UPDATE

Required on engines built before 8NM1890 that have the 7E1496 Dry exhaust elbow w/o slotted mounting holes.

1 - 1373892 Exhaust Elbow (Dry)
4 - 7X7729 Washer

OEM RISER MODIFICATION

Engines built before 8NM02820 or 6SR405 that DO NOT use Cat Riser, but DO use an OEM supplied riser: Modify or replace OEM riser and riser support.

ALTERNATOR MOUNTING BRACKETS
Not required on any 6SR or 4EZ engines.

1 - 1149102 - Bracket for 105 Amp alternator (As required on 105
Amp alternator only, before 8NM02100)

(or)

1 - 1175155 - Bracket for 51 Amp alternator (As required on
51 Amp alternator only, before 8NM01950)

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product smu/age	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
Unlimited	100 %	*	0	0	0	0

*Labor Hour Breakdown (In Boat Repair)

SMCS Code Hours Description

3.0 R&I Hatches
1100-010 22.0 R&I Cylinder Head, Turbo, Manifold *
1361-000 0.5 R&I Water Pump
1361-002 0.5 Repair Water Pump
1405-010 1.0 R&I Alternator Brackets
1100-001 2.6 Repair Cylinder Head
1000-072 1.0 Paint Parts (each engine)
1.0 Clean Boat (each engine)
1000-030 1.0 Test after Repair (each engine)

* 9 hours to R&I Cylinder Head in shop

NOTE: Up to $400.00 may be claimed to modify or replace
OEM Supplied exhaust riser.

NOTE: Caterpillar Marketing requests documentation of customer name and mailing address for future customer comunications. As a condition of payment of this PSP, the Dealer is required to document the owner's name and mailing address in the Caterpillar Product Information System (PIS), Screen J1Z111/05, and in the text of the claim story.

NOTE: Travel time and mileage for those engines outside the standard warranty period will be handled as if they were in the standard warranty period.

PARTS DISPOSITION

In North America, as a condition of payment for this PSP, if this PSP is done after a failure and and the engine is replaced, the failed engine must be returned to Caterpillar:

Caterpillar Service Claims

Attn: Jerry Anderson - PS4486
8201 N. University
Peoria, Il 61615 Return Turbochargers to Corinth Mississippi for core credit.

Return the Rack Control Linkage to:

Caterpiller Service Claims

Attention: Craig Berger - PS4486
8201 N. University
Peoria, Il. 61515 Scrap all other parts.

Attach. (1-Rework Procedure)

Rework Procedure

Table Instructions By Effective Serial Number

Effective
Serial Number Description

8NM1-1729 Check injector holddown bolt. Use only the
stronger 1395925 bolt.

8NM1-1950 If used, check 1175155 (51Amp) Alternator
bracket for cracks. Replace as necessary.

8NM1-1974 If Cat exhaust riser is used, replace with
new 1369081 Exhaust riser with slotted
mounting holes so it can be rotated back to
original exhaust position.

8NM1-1975 For RH fuel filter service, add clip to
1199293 Fuel filtersupply tube as
(Ref 1290914 Fastener Gp)
New vent fitting required in exhaust manifold.

8NM1-2100 If used, check 1149102-02 (105 Amp)
Alternator bracket for cracks. Replace as
necessary.

8NM1-2209
6SR1-206 New bolts required to mount exhaust manifold
to cylinder head.

8NM1-2664
6SR1-274 Replace turbocharger mounting studs in
exhaust manifold with Longer 9X8281 studs

8NM1-2820
6SR1-405 Do Schwitzer Turbocharger and manifold
update (or manifold update)
NOTE: This does not apply to 470hp RIB
boats.

8NM1-3197
6SR1-598
4EZ1-31 Do engine valve and water pump update.
Inspect rivet in Rack Control Assembly
per TIB.
Clean Aftercooler core.
Change to single grade CF-4 oil.

ACTION REQUIRED:

Drain Oil and Coolant.
Remove Rack Control Assembly and Fuel Injectors from cylinder head.
Inspect Rivet that retains the governor link to the rack bar per TIB dated April 22, 1998 (Component code: 1298). If the rivet is not TIGHT, replace the Rack Control Assembly and report per TIB instructions.
Remove the cylinder head, Aftercooler, Turbo, exhaust manifold, and Riser support bracket per the Service Manual.
Use Hydrosolve solvent (or solvents that contain toluene, acetone, or naphtha) to clean Aftercooler core and breather (Ref OMM)
Remove water pump group from the engine.
Replace water pump assembly in pump Group.
Install reworked water pump group on engine.
(8NM1-2100) Inspect Alternator mounting bracket for cracks
Replace mounting brackets as necessary.
Remove the 1136180 Intake valves from cylinder head.
Remove the 1014541 Exhaust valves from cylinder head.
Dress each exhaust valve seat. Maintain distance from head of exhaust valve to the cylinder head face of 1.51 to 2.22 mm (0.059-0.087 in)
Dress each intake valve seat. Maintain distance from head of intake valve to the cylinder head face of 1.13 to 2.05 mm (0.044 to 0.081 in)
Ream or replace(and ream) fuel injector sleeves to get good seat for injector cone.

NOTE: It is not necessary to completely remove the sealing ring indentation in the sleeve if it is uniform all around. Refer to March 1999 Engine News on how to use the new 1709227 Reamer Shims.

Install (6) new 1577125 - Intake Valves in cylinder head.
Install (6) new 1577126 - Exhaust Valves in cylinder head.
Install new valve stem seals.
Install the reworked cylinder head on the engine. (Lubricate head bolts with 6V4876 Molly Lubricant.)
Inspect injector cone seating surface for damage. Replace injector as necessary.
Remove tip o-ring from injector (Install new top O'ring) and install injector.
(8NM1-1729): check injector hold-down bolt part number. Use only 1395925 hold-down bolt and 9X8267 washer. This bolt has approx 3/8 inch un-threaded shank below the bolt head. Most engines will already have this bolt.
Hand torque to 14nm (10 lb-ft).

NOTE: When it becomes availablem the new Injector Seating Tool should be used to seat the injectors to eliminate combustion gas leakage.

(8NM1-2819, 6SR1-404): Install new Schwitzer Turbo and Exhaust manifold update, as required.

NOTE: Prelube turbocharger by adding clean engine oil to the turbo oil inlet and rotating the turbo shaft by hand. Check for interference between turbo mounting flange boss and manifold. Grind boss if necessary to provide clearance.

NOTE: If engine does not have AirSeps, the following modification is required:

1493242 Hose - Cut 1.0 in. off of short end, cut
2.5 In. off of long end. Install
long end to Turbo
1341843 Bracket - Also required 25.(8NM1-1973): Install new exhaust riser if required, rotate Slotted Cat exhaust riser outlet outward to original position and install new riser bracket.

26. If Boat has OEM installed (Non-Cat) riser, modify or replace riser, riser support, and/or exhaust piping in boat.

27. (8NM1-1975) and only for RH service fuel filter: Add bracket and clip to fuel filter supply tube assembly.

28. Change oil and filter using only a single grade oil that meets API CF-4 requirements.

Caterpillar Special Application Engine Oil meets
F4 and is available for use:
1705262 SAE 30
1705261 SAE 40

Other known Oils are:

In North America, Shell(USA) Rotella-T SAE 30W,
or Exxon XD-3 Extra 30W currently meet CF-4
requirements.

Outside of North America Shell (International)
SL0293, and Castrol (Australia) CRB 30 currently
meet API CF-4 requirements

-Refill quantity including filter is 25 liters if an auxilliary oil filtering system is not used. Check/correct dipstick full mark vs. oil level.

-Instruct the Customer to use ONLY these oils in future oil additions or changes to prevent fouling of Turbocharger and aftercooler.

29. Write the acceptable oils in the Owner/Operator Manual.

30. Refill cooling system. Pressure test cooling system and correct any leaks.

31. If conditions permit, run 1/2-hour loaded engine test in boat. After jacket water temperature is up to 180F, Run 20 minutes @ 2500rpm & 10 minutes @ full throttle. Engines should run 2800+ RPM at full throttle with 33-35 psi boost and very little combustion gas in fuel return line.