0305200 JOHNSON PLATE, Cover

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 "PS8757" 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.
Termination Date
September 30, 1997Problem
The hoses and fittings in the 1263566, 1263576, 1262637, and 1252420 Turbo Wash Lines Group may deteriorate due to exhaust heat and engine vibration on certain 3606, 3608, 3612, and 3616 Heavy Fuel Operation Engines.
Affected Product
Model & Identification Number
3606 (8RB558, 8RB585, 8RB590, 8RB591)
3608 (6MC310, 6MC311, 6MC313, 6MC332, 6MC333, 6MC380, 6MC410, 6MC411, 6MC480-482, 6MC488-491 )
3612 (9RC121, 9RC130, 9RC131, 9RC143, 9RC187, 9RC188)
3616 (1PD82-85, 1PD103, 1PD104, 1PD108-110, 1PD112-115, 1PD117, 1PD119-143, 1PD148 , 1PD154, 1PD156-161, 1PD163, 1PD165, 1PD167-175, 1PD177, 1PD179, 1PD185-188 , 1PD198-207, 1PD212-215, 1PD217, 1PD238, 1PD241-244, 1PD253-255 )
Parts Needed
Order parts by Engine Model designation.
In-line Engines (3606, 3608)
1 - 8C9024 Nipple Assembly2 - 1252422 Nipple2 - 1342594 Valve Vee Engines (3612, 3616)
2 - 8C9024 Nipple Assembly4 - 1252422 Nipple4 - 1342594 Valve Tool Group (1271508)
1 - 0094440 Connector1 - 8C9025 Coupler1 - 4K2430 Tee2 - 9X2350 Hose (24")4 - 9X3634 Coupling1 - 1383811 Coupler2 - 1383812 Coupler Exhaust Back Pressure Tool Group
1 - 0619463 Connector1 - 8S7169 Coupling1 - 8T0848 Gauge1 - 1180280 Coupling1 - 1245993 Hose Assembly1 - 1383812 CouplerAction Required
Remove the following parts as indicated by the Model Designation and replace with the parts listed in the "Parts Needed" section of this letter.
3606 (1263566)
1 - *3B7749 Nipple (remove one at 8C9025 Coupler)1 - 8C6905 Nipple1 - 8C9025 Coupler2 - 7L7262 Union1 - 5P3166 Tee1 - 6V2481 Union2 - 1243462 Valve1 - 1254125 Hose Assembly1 - 1259241 Nipple 3608 (1263576)
1 - *3B7749 Nipple (remove one at 8C9025 Coupler)1 - 8C6905 Nipple1 - 8C9025 Coupler2 - 7L7262 Union1 - 5P3166 Tee1 - 6V2481 Union2 - 1243462 Valve1 - 1245993 Hose Assembly1 - 1259241 Nipple 3612 (1262637)
2 - *3B7749 Nipple (remove one at each 8C9025 Coupler)2 - 8C6905 Nipple2 - 8C9025 Coupler4 - 7L7262 Union2 - 5P3166 Tee2 - 6V2481 Union4 - 1243462 Valve2 - 1254126 Hose Assembly2 - 1259241 Nipple 3616 (1252420)
2 - *3B7749 Nipple (remove one at each 8C9025 Coupler)2 - 8C6905 Nipple2 - 8C9025 Coupler4 - 7L7262 Union2 - 5P3166 Tee2 - 6V2481 Union4 - 1243462 Valve2 - 1245993 Hose Assembly2 - 1259241 NippleAction Required Cont.
Tooling Update
1. Remove the nipple and adapter from the existing drain tube.2. Add a 0094440 connector and an 8C9025 Q-disk Coupler.3. Attach the 9X3634 Couplings to the 9X2350 Hoses.4. Connect the hose assemblies to the 4K2430 Tee.5. Connect the 1383812 Coupler to the other end of the hose.6. Connect the 1383811 Coupler to the tee. This coupler will connect to the existing hose assembly.
Service Claim Allowances
Labor Breakdown Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.