16768A 1 Mercruiser GEAR SET

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 "PS4752" 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
August 31, 2000Problem
The emission version of the 3046 engine in certain 315 and 315B Excavators may experience excessive white smoke during initial startup. The problem is due to incomplete combustion. An air inlet heater needs to be added.
This program is valid only for 315 and 315B Excavators in the specified serial number range and built with the EPA emission engine.
Affected Product
Model & Identification Number
Group 1
315 (4YM371-418 (Engine Ar. 134-7000 only)
315L (6YM1914-1915, 6YM1917-2557) (Engine Ar. 134-7000 only)
Group 2
315B (1SW1-249) (Engine Arrangement 131-8979 only)
315BL (3AW1-1439) (Engine Arrangement 131-8979 only)
315BFM (7RZ1-284) (Engine Arrangement 131-8979 only)
Group 3
315B (1SW250-254) (Engine Arrangement 131-8979 only)
315BL (3AW1440-1863) (Engine Arrangement only)
315BFM (7RZ285-287) (Engine Arrangement only)
Parts Needed
Group 1
5 - 7Y3951 TERMINAL1 - 7Y5494 TERMINAL1 - 1046573 PLUG CONNECTOR2 - 7N7779 SOCKET1 - 8T8799 BOOT1 - 1028807 PLUG KIT1 - 1043204 CONTROLLER1 - 1160114 SWITCH AS1 - 1666124 HEATER KITSupplies not available through the Caterpillar system
50 cm - 16-gauge green wire50 cm - 4-gauge red wire4 meters - 4-gauge yellow wire 61 cm - 16-gauge red wire41 cm - 16-gauge purple wire1.2 meters - 16-gauge black wire1 - Male Sure Seal Connector Terminal1 - in Ring Terminal1 - Butt Connector - Heat Shrink TubeGroup 2
2 - 7N7779 SOCKET1 - 8T8799 BOOT1 - 7Y3951 TERMINAL1 - 1028807 PLUG KIT1 - 1043204 CONTROLLER1 - 1160114 SWITCH AS1 - 1666124 HEATER KITSupplies not available through the Caterpillar system
3 Meters - 4-gauge red wire4 Meters - 4-gauge yellow wire50 cm - 16-gauge green wireGroup 3
2 - 7N7779 SOCKET1 - 8T8799 BOOT4 - 7Y3951 TERMINAL1 - 1028807 PLUG KIT1 - 1043204 CONTROLLER1 - 1160114 SWITCH ASSupplies not available through the Caterpillar system
3 Meters - 4-gauge red wire4 Meters - 4-gauge yellow wire50 cm - 16-gauge green wireAction Required
See the attached Rework Procedure.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
Group 1 (315 Excavators)
Check to insure that the glow plug circuit operates correctly. During activation check that the glow plug indicator illuminates on the monitor panel. This indicator is located in the bottom left of the monitor display. (There is a 25-30 second delay before the indicator will light up.)
Turn off the Master Disconnect Switch
ENGINE REWORK - Refer to Illustration 1
1. Remove the 2 clamps and the Intake hose from the turbo to intake elbow.2. Remove the injection line clamp and remove the 4 bolts that secure the intake elbow to the intake manifold and remove the elbow. Remove the old gasket and clean the surface of the intake manifold.3. Install the 5M6214 plug into the side of the 166-6115 Elbow.4. Install the 517678 Gasket and 166-6115 Elbow on the intake manifold with two 6V3940 Bolts (short) and two 5P8347 Bolts (long). Install the injection line clamp and secure it to the 116-6115 elbow.5. Place the 5I7677 Gasket and heater assembly on the 5I8021 Elbow. Check that the airflow direction arrow located on the terminal stud side of the heater assembly is pointing down toward the intake. Also make sure the Power and ground studs are facing to the rear of the machine.
6. Place a 5I7678 gasket on top of the heater assembly.7. Install the 166-6113 Hose and clamps loose on to the 5I8021 elbow.8. Install the 166-6113 Hose and elbow assembly to the turbocharger and heater assembly.9. Secure the 5I8021 elbow and heater assembly with four 5P8347 bolts and tighten the hose clamps to the elbow and turbocharger. Secure the heater assembly ground wire with one of the bolts. Check for Continuity from the ground stud on the heater assembly to frame ground.
10. Disconnect 877YL Glow Plug Wire and cutoff the terminal. Remove this wire from the P-clip, tape off the end and tie out of the way (This wire will no longer be used). KEY SWITCH REWORK - Refer to Illustration 2
1. Remove four 7Y3173 Screws, that secure the 4I3166 Key Switch panel to the right console. Locate the 310-PU wire that is connected to the R1 and R2 terminals of the key Switch. Cut the short section of wire off of the harness that goes from terminal R1 to R2 and discard. Tape off any exposed wiring. Connect the 310-PU to terminal R2. Before modification the 310-PU is used to engage the glow plug relay. After the modification the 310-PU wire will be used to trigger the 104-3204 controller to go into a post heat timer function when the starter motor is engaged.
2. Install the 4I3166 Key Switch Panel. RELAY PANEL - Refer to Illustrations 3. 4. 5, and 6
1. Remove the fuse panel cover located on the relay panel. Remove the four 8T4191 bolts that secure the 4I5444 cover to the relay panel and remove the cover. Refer to Illustration 3.2. Mount the 104-3204 controller to the right inside of the relay panel box. Refer to Illustration 6 for dimensional information. Locate the (403-GN-18) wire going into connector 11 for the (094-2080) Starter