806222 16 Mercruiser HOSE

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 "PS8509" 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, 1996Problem
The engine factory test horsepower has been increased slightly to assure the minimum advertised tractor PTO horsepower. The "advertised" horsepower did not change. The slight increase in engine static fuel setting is adaptable to earlier CH45 Machines, per the attached procedure.
Affected Product
Model & Identification Number
CH45 (1DR1-829, 1DR837, 1DR839, 1DR841-845, 1DR849, 1DR895, 1DR898, 1DR900-903, 1DR917)
Parts Needed
1 - 1192940 Gasket1 - 1210172 PlateAction Required
See the attached Rework Procedure.
Service Claim Allowances
This is a 4-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
A 2% increase in the factory test horsepower (Gross Hp) has been implemented in production to assure the minimum advertised PTO-horsepower. The "Advertised" power did not change.
A similar change was made to CH35 engine performance specifications prior to the beginning of production. Therefore, ALL the CH35 Tractors were shipped with a similar change already in effect.
For the CH45 Machine, with the 1088300 Engine Arrangement, the following changes were made. The static Fuel Setting was INCREASED by 0.13mm.
The new CH45 Performance Specification, 2T7528, was effective in production with Engine S/N 98Z12152 - Up. Some earlier CH45 Machines/Engines were updated in the factory and the field, and can be identified by the new 2T7528 Performance Specification Number on the Engine Identification Label.
ADAPTABILITY: Earlier CH45 Machines with Engine S/N's 98Z1-12151 can be changed to the new specifications by re-setting the static Fuel Setting. This should be done by adding 0.13mm to the static Fuel Setting listed on the Engine Information Label. Re-set the Fuel Setting to this new specification. In addition, the Engine Identification Label must be changed, to show the new 2T7528 Performance Specification number, and the new calculated static Fuel Setting for future engine service. Again, the new Fuel Setting is calculated by adding 0.13mm to the original static fuel setting shown on the original Engine Information Label. Be sure to install a new dealer lock wire and seal after the fuel setting is re-set.
The former metal Engine Information Plate is no longer used on the U.S. produced engines. A film (label) is now used in production, covered by a clear laminate film for UV protection. When new "data plate" information must be shown on the engine, a metal replacement plate, p/n 1210172 must be installed. Dealers must "stamp" all the information on the new plate, including the new "2T" Number and the new Static Fuel Setting Specification. Use number and letter stamps 3mm high ( inch, 0.125 inch). Number and Letter hand stamping kits (steel type sets for hand stamping) must be procured locally from an industrial supply company, or machine shop supply company. To attach the replacement metal Information Plate, use an adhesive that is suitable for high temperatures, such as 8T9021 Adhesive, or equivalent.
When this update is performed, be sure to include a comment on the Service Report, such as: Comment: "2T7528 Rack Setting".
Fuel Timing Inspection:
While setting the static fuel setting, it is also recommended to check the fuel timing of the unit injectors. The fuel timing specification is shown on the Engine Information Label, and this specification has not changed. The "2T" Specifications in the TMI contain a nominal fuel timing dimension.
However, it is possible for each CH45 Engine to have a slightly different fuel timing specification shown on the Engine Information Label. This is because of a more accurate cylinder fuel timing method used at the factory which corrects for some tolerance variations in the parts. At the completion of the factory fuel timing procedure, the resulting "base circle" timing dimension is checked, and that "customized" fuel timing number is shown on the information label for field service, and may be different from one engine to another. The fuel timing specification shown on the Engine Information Label is the most accurate for that engine.
The factory sets the actual fuel timing to a 0.15mm smaller dimension (shorter, more advanced) to allow for "break-in" of the injector lifter and rocker arm mechanism. The specification shown on the Engine Information Label does not reflect this "break-in" allowance. Therefore, when checking new engines with less than 100 hours, the measured fuel timing may be found to be at a slightly smaller (shorter) dimension than shown on the plate, and this is normal and acceptable. Within the first 50-100 hours of engine operation, the break-in wear of injector mechanism components should be complete, and the measured fuel timing should be very close to the specification shown on the Engine Information label.
Valve Cover Gasket: A new 1192940 Valve Cover Gasket is included, if needed. When replacing a former cork-type gasket, be sure to clean the gasket material and adhesive from the valve cover. Use 4C4079 Component Cleaner, or equivalent for cleaning valve cover. The new 1192940 Gasket should be installed dry, without any adhesive or gasket cement. Tighten the valve cover bolts to a torque of 12Nm, using tightening sequence shown in the Service Manual.