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PSP FOR FRONT TIMING GEAR FAILURES ON CERTAIN 3208 TURBOCHARGED AFTERCOOLED MARINE ENGINES USED IN PLEASURE CRAFT APP LICATIONS - PS0405 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA, MARINE TEPS
  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.
U-170 A-116 AU-114 E-77 O-105 TM-6 1218, 1288 PS0405 This Program can be administered after a failure or before a failure occurs only as described in the "Action Required" section. The decision whether to apply the Program is made by the dealer. Contingent damage to the engine will be allowed, but must be explained on the claim. When reporting the repair, use "PS0405" as Part Number, "7755" as Group Number, and "96" as Description Code. Termination Date
December 31,1990
Problem
There have been some failures of the gear teeth on the engine camshaft gear assembly and/or fuel injection pump drive gear on later 3208TA Marine Engines. These are engines used in pleasure craft applications that are rated at 355 or 375 hp and have an 18.0 deg. BTC fuel injection timing (static) with no timing advance. (A solid gear is used instead of a timing advance unit.) Earlier 355 hp engines had a 15 deg. BTC fuel injection (static) timing with a 5 deg. automatic timing advance unit and are not included in this program. Current production engines now have a 15 deg. BTC fuel injection (static) timing and a 3.5 deg. automatic timing advance unit.
Affected Product
Model Identification Number 3208 TA 1Z3842-3869, 4041-5977, 5979-5981, 5983, 5990-6016, 6019-6024, 6029, 6031, 6032, 6034. If built to engine arrangements 1W9350 and 7W7500. Some of these engines may have already been reworked. Engines that have been reworked can be identified by "15.0 deg. BTC Fuel Timing" stamped on the Engine Information Plate.
Parts Needed
1-9N5858 Camshaft (Fuel Pump) 1-7C2856 Gear and Weight As. 1-6V3795 Front Structure Gasket Kit 1-4W5140 Engine Information Plate 1-9L8016 Oil Pan Gasket
Action Required
If a failure occurs, the new parts should be installed. If an engine in a multi-engine application fails, the other engine(s) may be reworked at the same time if they are listed in the Affected Product above. It will be necessary to remove the engine front housing and the fuel injection pump to make the repairs. After the new parts have been installed recalibrate the fuel injection pump. With the installation of the new parts the fuel timing and performance specification number will change. Stamp the engine information on the new 4W5140 Plate. The new Fuel Timing and Performance Specification are shown in the chart. After the information has been stamped on the new plate, install the new plate over the existing engine information plate. Engine Horsepower Performance Specification Fuel Timing 355 hp 0T6441 15.0 BTC 375 hp 0T6428 15.0 BTC
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested smu Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. (C/L) (Sell) (C/L) (Sell) 0-500 100% 18.5 0 0 0 0 501-1000 100% 0 0 0 0 18.5 This is a 18.5-hour job. The labor shown is the time allowed to install the new parts when the engine is out of the hull. Additional time will be allowed to disconnect and reconnect the engine to the driven equipment. This additional time must be explained in the claim.
Parts Disposition
Handle the parts