7745640_009 Volvo.Penta sprocket

August 26, 2000
(Revised January 2004)
U-240
A-176
AU-141
S-106
O-200
TT-4
Afterfailure only PRODUCT SUPPORT FOR REPLACING THE CYLINDERHEAD GASKET AFTER A FAILURE HAS OCCURRED ON CERTAIN C-10 AND C-12 TRUCKENGINES
1100 PS50041
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50041" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. The information supplied in thisservice letter may not be valid after the termination date of this program.Do not perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. If the cylinder head has beenremoved for another reason claim ONLY THE NEW HEAD BOLTS AND STUDS (ifequipped with a Compression Brake) under PS50041. This Revised Service Letter replacesthe August 26, 2000 (Revised July 2003) Service Letter. Changes have beenmade to the Termination Date.TERMINATION DATE
May 31, 2004PROBLEM
The cylinder head gasket may allow coolantto leak into the lubrication oil on certain C-10 and C-12 Truck Engines.
If PS50041 has been appliedto an engine after September 2001, that specific engine will no longerbe eligible for a second claim against PS50041 or any head gasket repairwith out Service Representative Authorization. A Service Rep. Authorizationwill have to be submitted in the claim story on any repeat claims to PS50041after September 2001.PARTS NEEDED
Parts Group A - ALL ENGINES
Individual parts MUST BE USED.If gasket kit is claimed it will be paid at 70%.4 - 1182797 Gasket (water manifoldto cylinder head).6 - 4G4972 O-Ring Seal (cylinder blockto cylinder head).1 ? 7E5555 Gasket (water pump tubeadapter to regulator housing)2 - 7L6580 O-Ring Seal (seals for waterpump tube)1 - 1013125 Air Inlet Gasket1 - 9Y1758 Breather-Gasket6 - 9X7557 Injector Seal6 - 1198784 Injector Seal6 - 9X7317 Injector Seal
PARTS REQUIRED FOR THE TURBO SUPPLYAND DRAIN LINES FOR MOST ENGINES (FLAT FLANGES)1 ? 8H9788 Gasket (turbo supply line)1 ? 1886126 Gasket (turbo drain line)4 ? 6V5218 Bolt (turbo supply and drainlines)(See Diagram)4 ? 6H7127 Spacer (turbo supply and drainlines)(See Diagram)
PARTS REQUIRED FOR TURBO SUPPLYAND DRAIN LINES FOR ALL OTHER ENGINES (STEPPED FLANGE)1 ? 8H9788 Gasket (turbo supply line)1 ? 1886126 Gasket (turbo drain line)4 ? 8T0276 Bolt (turbo supply and drainlines)(See Diagram)1 ? 4K5824 Spacer (turbo supply and drainline)(See Diagram)3 ? 9G8661 Spacer (turbo supply anddrain lines)(See Diagram)
CYLINDER HEAD GASKET INDENTIFICATION
CHART 1
Cylinder Block Configuration Cylinder Head Configuration Use Head Gasket Part Number
Straight Straight 187-3307
Straight Scalloped 187-3306
Scalloped Scalloped 187-3306
Scalloped Straight 187-3306 Block View Head ViewParts Group B - for use on C-10 and C-12 engine serial numbers
1YN1?up, 9NS1?16227, 2KS1-388, 2PN1-up,
8YS1-5388, 3CS1-7181 - 1873306 Cylinder Head Gasket (MUST BE USED WHEN YOU HAVE ASCALLOPED HEAD AND BLOCK OR STRAIGHT-SCALLOPED HEAD AND BLOCK COMBINATION.SEE CHART 1.)Parts Group C - for use on C-10 and C-12 engine serial numbers
9NS16228-20095, 2KS389-57687, 8YS5389-7578,
3CS719-175681 - 1873307 Cylinder Head Gasket (MUST BE USED WHEN YOU HAVE A STRAIGHTHEAD AND BLOCK ONLY. SEE CHART 1.)Parts Group D - for all engine serial numbers withoutcompression brake26 ? 1293184 BoltParts Group E - for all engine serial numbers withcompression brake23 ? 1293184 Bolt3 - 1787508 StudACTION REQUIRED
PRIOR TO MAKING A HEAD GASKET REPAIRTHE TECHNICIAN MUST
BE TRAINED BY USING THE C-10/C-12HEAD GASKET REPAIR
PROCEDURE VIDEO LEVN5101 OR LEVP5101.
Confirm the engine has coolant in theoil using an Oil Sample to identify a failure. Sodium (Na) or Potassium(K), and Soot readings must also be included. Use the following limitsfrom the Chart 2 below:
A complete copy of the actualoil sample results will be required, and must exceed the published limitsfor this service letter to apply.CHART 2
If SOS results show Positive for Antifreezeor Glycol, continue to step 2.
If extended oil drain intervalsare being used beyond Caterpillar recommendations indicated with chart2, the oil sample is not valid and this service letter does not apply.It is required to change the oil and resample within the chart limits.
Must test for Na (Sodium) if using Standardcoolant.
Must test for K (Potassium) if using ELCcoolant.
Use chart below to determine whether toinvestigate a coolant leak into oil.
Only if your readin