16012 Mercruiser HOSE, THERMOSTAT HOUSING TO FLUID COOLER

This Program must be administered as soon as possible. When reporting the repair, use "PI10010" as the Part number and "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 "PI10010" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
The information supplied in this service letter may not be valid after the of this program. Do not perform the work outlined in this Service Letter after the without first contacting your Caterpillar product analyst.
This Revised Service Letter replaces the June 1, 2000 (Revised July 2000) Service Letter. Changes have been made to the Affected Product.
Problem
The engine harness mounting needs to be corrected on certain D3C, D4C, D5C Track Type Tractors and 933C and 939C Track Type Loaders. Some machines have a problem where the engine harness can wear into the number 5-injector line. The harness needs to be mounted so that it is not allowed to contact the injector line.
Affected Product
Model & Identification Number
D3C III (6SL2716-2740, 6SL2742-2746, 6SL2748-2754, 6SL2756-2763, 6SL2765-2787, 6SL2789-2796, 6SL2798-2812, 6SL2814-2829, 6SL2831-2838, 6SL2840, 6SL2842-2868, 6SL2871-2875, 6SL2877-2888, 6SL2890-2899, 6SL2901-2934, 6SL2936-2939, 4KS395-447, 4KS449-538, 4KS540-555, 4KS558-700, 4KS702-764, 9TS304-476, 4TS348-399, 4TS401-413, 4TS415-445, 4TS447-479, 4TS481-507, 4TS509-625, 4TS628-847, 4TS849-894, 7XL1301-1522, 5GS274-311, 5GS314-320, 5GS322-333, 5GS335-366, 5GS373-384, 5GS386-457, 5GS460-517, 5GS519-567, 5GS569-572, 5GS574-591)
D4C III (6YL2106-2109, 6YL2111-2117, 6YL2119-2120, 6YL2122-2163, 6YL2165-2251, 6YL2253-2277, 6YL2279-2299, 6YL2301-2320, 7SL754-889, 6BS321-405, 6BS407-424, 6BS426-481, 6BS483-523, 6BS525-528, 6BS530-557, 6BS559-585, 4LS257-283, 4LS286-318, 4LS320-388, 4LS393-394, 4LS396-450, 4LS452-466, 6BS407-424, 6BS426-481, 6BS483-523, 6BS525-528, 6BS530-557, 6BS559-585, 8CS474-579, 8CS581, 8CS583-758, 8CS761-773, 8CS777-872, 8CS874, 8CS876-904, 8CS906-965, 8CS967-1017, 1FW337-478)
D5C III (9DL2374-2400, 9DL2402-2428, 9DL2430-2441, 9DL2443-2504, 9DL2506-2509, 9DL2511-2530, 9DL2532-2545, 9DL2547-2549, 5HS364-557, 5HS559-677, 5HS679-689, 5HS691-700, 5HS702-742, 8ZS277-476, 7PS506-614, 7PS616-674, 7PS676-695, 7PS697-717, 7PS719-919, 7PS921-981, 7PS983-1050, 7PS1052-1111, 7PS1114-1167, 6ZL918-1107, 6CS367-480, 6CS482-572, 6CS574-660, 6CS662-690, 6CS692-715)
933C (4MS292-301, 4MS303-327, 4MS329-337, 4MS339-354, 4MS356-371, 4MS373-395, 4MS397-406, 4MS408-416, 4MS419-427, 4MS429-433, 4MS435-439, 4MS441-453, 5JS337, 5JS339, 5JS341, 5JS343, 5JS345, 5JS348-349, 5JS351, 5JS355, 5JS357, 5JS359, 5JS365, 5JS367-368)
939C (6DS506-537, 6DS541-570, 6DS572-578, 6DS581-599, 6DS601-603, 6DS605-622, 6DS624-640, 6DS642-647, 6DS649, 6DS651-727, 6DS730-736, 6DS738-743, 6DS745-764, 6DS766-782, 6DS784-785, 6DS790-823, 6DS827-841, 6DS843-861, 6DS863-867, 6DS871-882, 6DS884-891, 6DS893-901, 6DS903-909, 6DS911-935)
Delta (05A11927, 11928, 11969-11972)
Parts Needed
1 - 5C7261 Nut1 - 4K8864 Clip1 - 4P8134 Clip5 - 3S2093 Strap - Cable1 - 8T4189 Bolt1 - 8T4224 Washer1 - 8T7934 Washer1 - 9Y2700 Spacer1 - 338248 Clip1 - 1253003 Bolt (If not available, use 1961856 Bolt)Action Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
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.
Attach.(1-Owner Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
1) Remove the harness P-clip (See Illustration 1). Then reinstall the bolt and washer on the fuel filter base. The new harness mounting hardware will use the front mounting bolt of the fuel filter (See Illustration 2). Do not use the rear mounting bolt.
Illustration 1.Top View of Engine
Illustration 2.New Harness Mounting Location
2) Remove the front fuel filter mounting bolt, this bolt and washer can be discarded.3) Install new harness mount hardware. Machines without Starting Aid-Ether or Heater (See Illustration 3). Machines with Starting Aid-Ether or/and Heater (See Illustration 4) Several straps may need to be cut and replaced to obtain adequate harness slack for the new mounting.
Illustration 3.Engine Harness Mounting
Illustration 4.Harness Mounting with Ether and/or Heater
Make sure the harness can not touch the fuel injector lines.
4) If the machine has Ether Aid secure the harness with 3S2093 Straps to the engine harness (See Illustration 4).5) Torque both fuel filter-mounting bolts.6) Drill the existing hole in the muffler bracket to 9-mm (.355 in.) diameter (See Illustration 5).7) Install 4P8134 Clip to muffler bracket using an 8T4189 Bolt, 8T4224 Washer, and 5C7261 Nut.
Illustration 5.Muffler Bracket
Some machines may already have this update to the muffler bracket.
8) Install 3S2093 Strap to the 4P8134 Clip and the Engine Harness.