87121-ZW8-S01 Honda MARK, RR. (8)

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.
This Program must be administered as soon as possible. When reporting the repair, use "PI3747" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3747" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
This Revised Service Letter replaces the February 5, 1995 Service Letter. Changes have been made to the application of the program and to the Service Claim Allowances.
This Program only applies to engines in dealer and dealer OEM inventory or that have been delivered to customer job sites but have NOT yet been started.
Completion Date
August 31, 1995Termination Date
February 29, 1996Problem
Some debris may have been left in the 4P5437 Gear Shaft in the rear gear train on certain 3508, 3512, 3516, G3508, G3512 and G3516 Engines.
Affected Product
Model & Identification Number
3508 (4ZL105 95Y944 96Y1465 , 96Y1467, 96Y1469, 96Y1495-1501 23Z5607 , 23Z5609, 23Z5610, 23Z5612-5616, 23Z5618-5622, 23Z5624-5634, 23Z5741, 23Z5742, 23Z5744-5761, 23Z5764-5767, 23Z5769-5771, 23Z5773, 23Z5775, 23Z5776, 23Z5779, 23Z5780 68Z831 69Z652-655 , 69Z671 70Z874 , 70Z875, 70Z877-884)
G3508 (2JF298, 2JF305-307)
3512 (2WK39 1LM42 , 1LM43 49Y740 50Y1282 , 50Y1284-1288, 50Y1290, 50Y1291 24Z5820-5830 , 24Z5832-5836, 24Z8538-5843, 24Z5845-5858, 24Z6011-6014, 24Z6016-6023, 24Z6025, 24Z6027, 24Z6028, 24Z6030-6032, 24Z6037, 24Z6038, 24Z6040, 24Z6041, 24Z6045 66Z577-580 , 66Z563-568 67Z1160 , 67Z1161, 67Z1163, 67Z1164, 67Z1179, 67Z1180, 67Z1197)
G3512 (4KC530, 4KC531, 4KC554, 4KC557, 4KC558 7NJ46-52 )
3516 (5SJ14 6CL105 , 6CL106 25Z3977-3984 , 25Z3986-4000, 25Z4003-4008, 25Z4010, 25Z4012-4020, 25Z4166, 25Z4168-4177, 25Z4182-4187, 25Z4192, 25Z4200, 25Z4217)
3516 (27Z746 29Z1103-1105 72Z464 73Z667-668 )
G3516 (3RC1021-1024, 3RC1045, 3RC1046 4EK245-246 , 4EK248, 4EK250-259, 4EK261-269, 4EK327, 4EK328, 4EK332, 4EK333)
Parts Needed
Dealers will need to order parts for this Program.
Order parts for repairs only if inspection of the engine rear gear train indicates a need for new parts.
1 - 7E2631 Gasket-Oil Pan1 - 7N3049 Gasket2 - 7N4319 Cover1 - 4P5437 Shaft-Gear1 - 4P5438 Bearing-Sleeve1 - 4P5459 Gear Assembly-Balance1 - 1138433 Seal Group-Crankshaft**A new 1138433 Crankshaft Seal Group is needed even if the inspection reveals no damage to the gear train.Action Required
Parts Stock
Inspect all 4P5437 Gear Shafts in Parts Stock received prior to November 20, 1994. If debris is found in the oil holes of the gear shaft, flush it out and return the cleaned gear shafts to Parts Stock.
Affected Product
1. Remove generator (if so equipped) to allow access to engine flywheel housing.2. Pin the camshaft and crankshaft.3. Remove the rear housing.4. Remove cluster gear and shaft and idler gears and shaft.5. Inspect shafts for debris of chips in the oil holes and clean them as needed.6. After cleaning, flush holes and inspect to assure that debris has been completely removed.7. Inspect the surface finish of the shafts.8. Inspect cluster gear and idler gear bearings for damage from debris or chips.9. If no damage is found in the gear train, replace only the 1138433 Crankshaft Seal, and assemble the engine.10. If damage is found, replace the bearing(s) or gear(s) as required. When bearing replacement is necessary, refer to Special Instructions, SEBF8188, "Specifications And Salvage Procedures For Rear Gear Train 3500 Family Of Engines" to machine the bearings to the correct dimensions.
Owner Notification
Not applicable.
Service Claim Allowances
Parts Stock
Submit one claim for all 4P5437 Gear Shafts inspected and cleaned. List .5 hour of labor at your cost rate for each gear inspected and cleaned.
US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.
Affected Product
Inspection Only This is a 15-hour job. If the engine is equipped with a generator, an additional 5 hours of labor may be claimed. If additional labor is needed due to the location of an engine at a customer's job site, reasonable labor may be claimed but must be explained in the claim story.
Inspection And Replacement of Components This is a 19-hour job. If the engine is equipped with a generator, an additional 5 hours of labor may be claimed. If additional labor is needed due to the location of an engine at a customer's job site, reasonable labor may be claimed but must be explained in the claim story.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.