09117-06039 Suzuki BOLT (6X25)

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PSP FOR SPACER PLATE ENGINES THAT DEVELOP COMBUSTION GAS LEAKAGE COMBINES INTO ONE PROGRAM - D8K 583K D9H 594H - PS0144 - M AILED US AND CANADA, CACO, COFA, CFEL, COSA, BRAZIL
  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.
PRODUCT SUPPORT PROGRAMS FOR SPACER PLATE ENGINES THAT DEVELOP COMBUSTION GAS LEAKAGE COMBINED INTO ONE PROGRAM, D8K, D9H Tractors; 583, 594H Pipelayers, 1201, 1216, 1217, PS0144 (see note) U-26 A-24 AU-21 B-12 C-25 E-23 See August 9, 1984 This new PSP (PS0144) replaces two former PSP's, designated as SLA087 and SLA102. Do not use either SLA No. The termination date has been extended. Problem Engines in some D8K and D9H Tractors and 583K and 594H Pipelayers with spacer plates between the cylinder block and heads have developed leakage of combustion gases into the cooling system. This leakage can subsequently erode the liner flange seats on top of the cylinder block. It then may become necessary to machine the block to accommodate seat inserts for the cylinder liners. The former PSP's have been combined into one Program to give uniform support and for easier policy administration. Also, all D8K Tractors and 583K Pipelayers produced are now included, and a machine maximum use time of six years for all models has been added. Please cross out the two former Service Letters on these models and refer both to this new Service Letter. The two former SL's are: April 29, 1979 (Revised August, 1981) SLA087 November 20, 1979 (Revised January, 1982) SLA102 Affected Machines And Parts All D8K and D9H Tractors and 583K and 594H Pipelayers with spacer plate engines are included in this Product Support Program (PSP) if they develop excessive gas leakage into the cooling system due to block erosion under the liner flanges. The serial number ranges are: (SEE ILLUSTRATION) The new parts available for D8K Tractors and 583K Pipelayers: 2 - 7N3353 Gasket (Spacer Plate) 2 - 8N4810 Head Gasket (has larger diameter wire for improved combustion gas seal) 6 - 8N4638 Filler Band (improved water seal) 6 - 8N6150 Insert (stainless steel) (1.595 mm or 0.0628" thick) OR 6 - 8N6742 Insert (stainless steel) (3.246 mm or 0.1278") thick) The new parts available for D9H Tractors and 594H Pipelayers: 2 - 1W6440 Head Gasket (was 8N7264) 2 - 7N3033 Gasket (spacer plate) 6 - 8N4708 Filler Band 6 - 8N6938 Insert (1.595 mm or 0.0628" thick) OR 6 - 8N6939 Insert (3.246 mm or 0.1278" thick) Engines with spacer plates are easily identified by the presence of the plates between the heads and block. Action Requested The purpose of this PSP is to provide adequate and consistent service support on machines if a failure occurs. Caterpillar will participate in Installing Two Inserts In One Counterbore For D9H Tractors Or 594H Pipelayers (Not Recommended For D8K Tractors Nor 583K Pipelayers) If the erosion depth is more than 3.175 mm (0.125"), counterbore the block deeper so two inserts can be used. Use one each of the two different inserts for the D9H, not two of the same thickness. : Using the inserts as a pair may increase or decrease the tolerance of the individual inserts. The variance in tolerance of the paired inserts will effect the depth of the counterbore to be machined. To machine the counterbore to the correct depth, put the two inserts together and measure the thickness with a micrometer in four places around the pair of inserts. Machine the counterbore depth according to the average measured