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PSP FOR OVERHEATING/COOLANT LOSS IN 3208 TURBOCHARGED MARINE ENGINES - PS0213 - MAILED WORLDWIDE
  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.
PRODUCT SUPPORT PROGRAM FOR OVERHEATING AND/OR COOLANT LOSS IN TURBOCHARGED 3208 MARINE ENGINES, 1371, 1380, 1364, 1388, PS0213 (Revised July, 1984) U-43 A-28 AU-35 B-15 C-40 E-25 O-31 TM-3 SEE OCTOBER 3, 1984 Scrap your copies of the May 15, 1984, Service Letter, Form SEBE3211, and replace it with this revised Service Letter. Problem Loss of engine coolant and overheating have been experienced on some turbocharged 3208 Marine Engines, especially 300 HP engines installed in pleasure crafts. Several factors can contribute to this problem, including high sea water intake temperature, engine load, antifreeze concentration in the coolant, coolant leakage past the gaskets in the water-cooled exhaust manifold, and customer maintenance. There have also been reports of the short water line hose loosening and coming off at the rear of the water-cooled manifold. To reduce the possibility of overheating problems, customers and OEM dealers are requested to check several maintenance items whenever overheating is experienced. Caterpillar dealers are requested to install larger hoses and fittings in the exhaust manifold to increase coolant flow on earlier engines. Also, a new temperature alarm contactor with a higher setting is to be installed. Similar improvements have been made in production. Affected Engines And New Parts Needed A. Engines Requiring Rework Of The Front Water Lines And Installation Of The Alarm Contactor Group Engines with serial numbers 1Z1 through 1Z3444 which have experienced overheating require rework of the exhaust manifold front water lines and installation of the new alarm contactor group. Some of these engines will also need to have the exhaust manifold rear water lines reworked (see Part "B" below). New Parts Needed * 2 - 4W1172 Cover 1 - 6B9081 Bushing * 2 - 9L8412 Plug 1 - 2W10 Elbow 2 - 7W1642 Gasket - 5P1251 Bulk Hose (8.3 - - 7W1890 Elbow cm/3.25" needed.) 1 - 7W1820 Elbow 1 - 9N237 Gasket 1 - 4J7207 Hose 1 - 5M6214 Plug 4 - 9M7958 Clamp 1 - 2N2920 Water Temperature Contactor * Order the 4W1172 Cover only if you decide not to modify the original cover as shown in Illustration 2. If the new 4W1172 Cover is used, then the new 9L8412 Plugs must also be used. B. Engines Requiring Rework Of The Rear Water Lines And/Or Side Manifold Modification Engines with serial numbers 1Z1 through 1Z3444 which experienced overheating may require rework of the exhaust manifold rear water lines and possible modification of the side manifolds. Refer to the chart under Action Requested, Part B, to determine which of these changes is needed. All of these engines also require rework of the front water lines and installation of a new alarm contactor group (see Part "A" above). New Parts Needed * 4 - 5P3179 Elbow 2 - 117219 Bushing 2 - 5P1251 Bulk Hose (6.35 cm/2.5" per hose is (needed) 2 - 7W1642 Gasket 2 - 7W1641 Gasket 2 - 5M6214 Plug 4 - 9M7958 Clamp ** 1 - 7W1890 Elbow * Two of these elbows will have to be modified to provide drain holes. See Illustration 5. ** Only required if inside diameter of 6V1293 Elbow does not meet requirement in Step A-6. Action Requested (Parts STock Action Not Needed) When overheating has occurred dealers are requested to make the following (normal) maintenance checks on all the affected engines before reworking the water lines. No Caterpillar participation is allowed for performing these maintenance checks (1 through 5). 1. Remove the raw water strainer and clean it thoroughly. Inspect the drain plug at the bottom of the marine transmission oil cooler located at the rear of the engine. Some earlier engines may have an incorrect magnetic steel plug installed. A brass drain plug (part number 127950) should be installed. 2. Inspect the raw water impeller. If it is damaged, install a new one. Refer to the December 12, 1982, Service Letter (revised December, 1983), PSP 146 for additional information. 3. Remove and inspect the 9N5121 Water Temperature Regulators. Install new ones if they are damaged or not opening correctly. Replace the regulators if there is any doubt as to their correct functioning. 4. Remove the end bonnets from the heat exchanger. Inspect the sacrificial zinc rods. Install new zinc rods if necessary. Inspect the heat exchanger core for any buildup of scale or foreign material on the inside or outside of the tubes. Clean the core as necessary. Install the zinc rods. If new zinc rods are needed, use part number 6L2289 when ordering. 5. Use a mixture of water and cooling system conditioner. Use antifreeze only if freeze protection is needed. Mix the ethylene-glycol type of antifreeze with the water in the concentration needed for the lowest expected outside temperature. To help prevent corrosion and pitting, add enough cooling system conditioner to provide a 3 to 6% concentration. Caterpillar dealers are requested to rework the front and/or rear water lines on the exhaust manifold and install the new alarm contactor group using the following procedures: A. Front Water Line Rework And Installation