0433521 JOHNSON MANIFOLD AT., Balance tube

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 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 "PS8761" 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.
1996 COSA mail code O-211 is not in order since it was added at Revision SEBE5838-02 in May 1997.
This Revised Service Letter replaces the September 7, 1996 (Revised May 1997) Service Letter. Changes have been made to the Termination Date, Parts Needed, Service Claim Allowances and Rework Procedure.
Termination Date
September 30, 1998Problem
The camshaft, roller followers, and/or front gear train components may fail in certain 3208 Industrial Engines.
Affected Product
Model & Identification Number
This Program applies only to specific 3208 Engine Serial Numbers within Engine Arrangement 1090682 (295 HP Tyler/MTC Machines).
Group 1
3208 (03Z11970, 03Z11981, 03Z11989, 03Z12093, 03Z12101, 03Z12141, 03Z12253, 03Z12261 , 03Z12262, 03Z12270, 03Z12306, 03Z12337, 03Z12339, 03Z12341 03Z12345 , 03Z12349, 03Z12352, 03Z12358, 03Z12360, 03Z12361, 03Z12364, 03Z12365 , 03Z12368)
Group 2
3208 (03Z11963, 03Z11966-11968, 03Z11971, 03Z11982, 03Z11983, 03Z11987, 03Z12100 , 03Z12110, 03Z12111, 03Z12117, 03Z12123, 03Z12128-12130, 03Z12138 , 03Z12140, 03Z12142, 03Z12188-12194, 03Z12260, 03Z12263-12266 , 03Z12271-12273, 03Z12282, 03Z12283, 03Z12292, 03Z12293 , 03Z12301-12303, 03Z12307, 03Z12308, 03Z12336, 03Z12342, 03Z12344 , 03Z12346, 03Z12348, 03Z12350, 03Z12351, 03Z12353-12357, 03Z12363 , 03Z12799, 03Z12800, 03Z12803, 03Z12804, 03Z12835, 03Z12838, 03Z12842 , 03Z12845, 03Z12847-12849, 03Z12889-12896, 03Z12906, 03Z12907 , 03Z12913, 03Z12917, 03Z12997, 03Z13011-13016, 03Z13021, 03Z13022 , 03Z13027-13029, 03Z13038-13040, 03Z13083-13087, 03Z13089 , 03Z13103, 03Z13155-13171, 03Z13177, 03Z13178, 03Z13332 , 03Z13381-13384, 03Z13391-13394, 03Z13397-13400, 03Z13424 , 03Z13462-13464, 03Z13468-13470, 03Z13473-13476, 03Z13480-13482 , 03Z13538-13544, 03Z13546-13548, 03Z13550-13553 , 03Z13563-13569, 03Z13612, 03Z13615, 03Z13616, 03Z13648 , 03Z13670, 03Z13675)
Group 3
3208 (03Z13691, 03Z13692, 03Z13696-13698, 03Z13700-13706, 03Z13708-13712 , 03Z13716, 03Z13719, 03Z13728, 03Z13793, 03Z13795 )
Parts Needed
Group 1
1 - 7C6660 Seal Group 1 - 7E2888 Gear 1 - 3J4538 Screw16 - 9N0141 Spring 1 - 6V3785 Gasket Kit 1 - 6V3789 Gasket Kit 1 - 6V6401 Gasket Kit 1 - 9Y5175 Rotor Assembly 1 - 9Y5215 Gear 1 - 1186671 Pointer 1 - 1213115 Damper Assembly 1 - 1227367 Washer 1 - 1258484 Camshaft Assembly 1 - 1264343 Pulley16 - 1329793 Lifter Assembly 1 - 1456103 Gear and Weight AssemblyThe following parts are required only if excessive valve guide wear has been identified (see rework procedure).
2 - 0R1101 Cylinder Head GroupGroup 2
1 - 7C6660 Seal Group 1 - 7E2888 Gear 1 - 3J4538 Screw16 - 9N0141 Spring 1 - 6V3785 Gasket Kit 1 - 6V3789 Gasket Kit 1 - 6V6401 Gasket Kit 1 - 1186671 Pointer 1 - 1213115 Damper Assembly 1 - 1227367 Washer 1 - 1258484 Camshaft Assembly 1 - 1264343 Pulley16 - 1329793 Lifter Assembly 1 - 1456103 Gear and Weight AssemblyThe following parts are required only if excessive valve guide wear has been identified (see rework procedure).
2 - 0R1101 Cylinder Head GroupParts Needed Cont.
Group 3
1 - 7C6660 Seal Group 1 - 7E2888 Gear 1 - 3J4538 Screw16 - 9N0141 Spring 1 - 6V3785 Gasket Kit 1 - 6V3789 Gasket Kit 1 - 6V6401 Gasket Kit 1 - 1227367 Washer 1 - 1258484 Camshaft Assembly16 - 1329793 Lifter Assembly 1 - 1456103 Gear and Weight AssemblyThe following parts are required only if the flywheel housing joint update is completed on any Group (See Rework Procedure).
1 - 7W3200 Seal Group 8C8422 SealantThe following parts are required only if excessive valve guide wear has been identified (see rework procedure).
2 - 0R1101 Cylinder Head GroupAction Required
See attached rework procedure.
Service Claim Allowances
Group 1
Service Claim Allowances Cont.
Groups 2 and 3
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1. Rework Procedure)Rework Procedure
Remove the existing components and install the indicated new parts following the standard procedures and specifications in the 3208 Industrial Engine Service Manual except for the additional details and specific procedures shown below:
Cylinder Head Inspection: Measure the exhaust valve guide wear on all cylinders.The wear must be within Reuse Specifications published in the 3200 Engine Reuse and Salvage Guide. If the wear exceeds reuse limits, replace the heads with 0R1101 Cylinder Head Groups.
Coolant Sleeves and O-Rings: Be sure to use the new 1097279 Coolant Sleeves and 1188586 O-Rings provided in the 6V3785 Head Gasket Kit.
Installation of Timing Advance: Use a new 3J4538 Screw and 1227367 Washer when replacing the Gear & Weight Assembly. Apply liquid 1E2200B Sealant (Blue Loctite #242) to the screw threads. Tighten the 3J4538 Screw to a torque of 7.9 0.6 N m (70 5 lb in), and "stake" to washer at two places.
Fan Drive Mounting Bracket: Remove the fan drive pulley group from the 6N6882 Bracket attached to the top of the front housing. Remove the four 0S1585, inch Bolts, from the bracket and apply liquid 1E2200B Sealant (Blue Loctite #242) to the threads. Assemble the bracket to the front housing and tighten to a torque of 120 20 N m (89 15 lb ft). Attach the fan drive pulley group to the bracket.
Flywheel Housing: This procedure is to be completed ONLY if the engine is not installed in the chassis, or has been removed from the machine for other reasons. If the engine is out-of-chassis, complete the following steps:
1. Remove Flywheel, Flywheel Housing, and Crankshaft Seal (standard D&A).2. Clean the flywheel housing to cylinder block contact surfaces. Both surfaces must be free of oil, fuel, water, and any other contaminants.3. Apply 8 mL of 8C8422 Liquid Gasket continuously to the flywheel housing mounting surface.4. Install the flywheel housing using liquid 1E2200B Sealant (Blue Loctite #242) on all mounting bolts, and tighten to a torque of 50 10 N m (37 7