8849 Mariner END CAP ASSEMBLY, COMMUTATOR

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PRIORITY:RETIGHTEN CRANKSHAFT COUNTERWEIGHT BOLTS; REPLACE BOLTS IF NECESSARY 3508, 3512 ENGINES - PI3005 - MAILED US AND CAN ADA, CACO, COFA, CFEL, BRAZIL, COSA
  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.
RETIGHTEN CRANKSHAFT COUNTERWEIGHT BOLTS; REPLACE BOLTS IF NECESSARY 3508, 3512 Engines, 1202, PI3005 U-25 A-23 AU-20 B-11 C-24 E-22 O-19 PRIORITY Problem The listed 3508 and 3512 Engines may have loose or improperly tightened bolts in the crankshaft counterweights. One or more loose bolts causes the bolts to bend and the connecting rod can interfere with the counterweight. This breaks the counterweight bolts and the weight is thrown through the block, usually destroying the engine. A special lubricant instead of engine oil is now used on the bolts to prevent any damage to the mating parts when the bolts are tightened, and a tighter torque-turn method is used. Affected Engines And Parts If Needed All the listed engines are included in this Priority Program. 3508 Industrial Engines 95Y1-95Y611, 613-616 3508 Industrial Engines - Slow Speed 68Z1-68Z675 3508 Marine Engines 96Y1-96Y584, 586-599 3508 Marine Engines - Slow Speed 69Z1-69Z252 3508 Generator Sets 23Z1-23Z448 3508 Generator Sets - Slow Speed 70Z1-70Z549 3512 Industrial Engines 49Y1-49Y354, 359, 360, 367, 379-382, 389, 390, 397, 404-408, 410 3512 Industrial Engines - Slow Speed 65Z1-65Z589 3512 Marine Engines 50Y1-50Y496 3512 Generator Sets 24Z1-24Z423, 425-431, 433-437, 439-443, 445-447, 449-479, 481-492, 494-500, 502-575, 577-640 3512 Generator Sets - Slow speed 67Z1-67Z485, 487-491 3512 Vehicular Engines 51Y1-51Y450, 452-454, 456, 458-461, 465-467 Parts needed, if any, are 1N3212 Bolts. Many engines will require none and some may require a quantity of new bolts. Action Requested The following procedure applies to all the engines listed. Do this work immediately, giving priority to users' engines. Take a quantity of new 1N3212 Bolts to the job site so new bolts can be installed if needed. Do the following procedure, one bolt at a time: 1. Loosen the crankshaft counterweight bolt about one full turn, noting whether or not the bolt seems to turn without any unusual amount of effort. If the bolt backs out one full turn and appears to be free of any unusual amount of effort or resistance, simply tighten the same bolt back to a torque of 50 +/- 5 N X m (37 +/- 4 lb ft). Now, tighten the bolt an additional 1/3 turn (120 +/- 5 deg.). OR 1a. If a bolt seems to require too much effort when it is loosened one full turn, remove the bolt. The bolt threads could be damaged. Do not use this bolt. 1b. Inspect the threads in the crankshaft and look for debris in the threads. 1c. Remove any debris and use a tap (5/8" - 18 UNJF threads) to clean up the threads. 1d. Using a new bolt, put Fel-Pro C100 compound on the new bolt threads, shank, and under the head to prevent damage when it is tightened. No other thread lubricant is acceptable. Please note this in all the 3508, 3512, and 3516 Service Manuals. A correction will be sent regarding the article in the February 28, 1983 Service Magazine. If necessary, North American dealers can obtain the name of the nearest Fel-Pro dealer from the following (other dealers see attached list of locations): FEL-PRO Inc. 7450 N. McCormick Blvd. Box C 1103 Skokie, IL 60076 U.S.A. Telephone: 312-761-4500 312-674-7700 TELEX: 4330156/TWX 910-223-3603 Cable: FELPROINC, SKOKIE 1e. Tighten the new bolt to 50 +/- 5 N X m (37 +/- 4 lb ft), being sure the bolt has no sudden increase in turning effort as you approach this torque. 2. Tighten the bolt an additional 1/3 turn (120 +/- 5 deg.). Warranty Allowances List any new bolts required on the claim. Caterpillar will contribute 4 hours labor at your selling rate for each 3508 Engine and 7.5 hours labor for each 3512 Engine. Complete each claim in accordance with your Warranty Bulletin on PIP's. Refer to January 17, 1983 Service Letter, Illustration 1, for new PIP number format. Type this bolt PIP as "PI3005". (COSA dealers see January 11, 1983 COSA General Letter.) Parts Disposition Dispose of any parts in accordance with the Warranty Bulletin, "Warranty Parts Handling". Termination Date March 31, 1984. Complete this Program as soon as possible. Payments on claims for failures after March 31, 1984 will be limited to the dollar amount of this PIP, which means the cost of replacing parts damaged by a failure will not be allowed. Attach. List of Fel-Pro Dealers Outside of North America Central Engineering & Supply Corporation, GPO Box 1312 San Juan, P.R. 00936 J. L. Gandara y Cia. S.A. Apartado 156 Bilbao, Spain C.G.D.I.P.L.I. B.P. 10 69270 Fontaines Sour Saone France Etablissements Jacques Carlier Avenue Van Volxem 380-386 B-1060 - Bruxelles, Belgium Tong Heng Long No. 773-775/1 New Road Talatnoi Bangkok 1, Thailand Chemiko Trad. Co. C.P.O. Box 5168 Seoul, Korea JOFRAN 21 Vitolion St. Pireaus 24, Greece Kubo-Tech Ltd. Lindauerstr. 21 8307 Tagelswangen Switzerland Gandara-Chile S.A. P. O. Box 131-V Valparaiso, Chile Mohammad Y. Al-Nisf P. O. Box Safat 871 Kuwait, State of Kuwait Te Foung Enterprises P. O. Box 67-242 Taipei, Taiwan NIPCO S.R.L. Via Padre G.A. Filippine 130 00144 Rome, Italy Wyler Enterprises 1300 Rizal Ave., Sta. Cruz Manila, Philippines Axel Larsson Maskinaffar A.B. Box 11052 S-16111 Bromma 11, Sweden Aidchim, Ltd. Industrial Zone, P. O. Box 103 Raanana, Israel Marine & Hardware (s) Pte. Ltd. No. 602, 6th