PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CYLINDER HEADS ON CERTAIN G3512C, G3512E, G3516C, G3520C, AND G3520E ENGINES Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CYLINDER HEADS ON CERTAIN G3512C, G3512E, G3516C, G3520C, AND G3520E ENGINES

Usage:

TEBE0767-01

04Apr2014
(Revised 09Jul2014)


U-183
A-138
D-171
O-160

 

Priority

  
 Parts stock action needed 

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CYLINDER HEADS ON CERTAIN G3512C, G3512E, G3516C, G3520C, AND G3520E ENGINES

1105 1100
PI32326
NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32326" 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 "PI32326" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.

NOTE:

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.

 
NOTE:

This Revised Service Letter replaces the 04Apr2014 Service Letter. Changes have been made to the Affected Product and Parts Stock Action Required.


COMPLETION DATE

TERMINATION DATE

31Oct2014 30Apr2015

PROBLEM

The cylinder heads need to be reworked on certain G3512C, G3512E, G3516C, G3520C, and G3520E Engines. The existing 3327386 Rotocoil Assembly can fail internally resulting in a loss of rotation of the valve.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
G3516C F6D00109-00113

F6F00108-00109

GZC00260-00262
*******Group  2*******
G3512E NGS00163

SSR00226-00231
*******Group  3*******
G3520C GZA00259-00264

GZB00250-00252

GZJ00663-00673

GZM00215-00217

GZN00881-00889

LGS00177-00179
G3520E  GZE00242-00262

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
16 9Y6792 GASKET-SPARK
16 2037859 GASKET
64 3165978 ROTOCOIL AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 35% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

*******Group 2*******
12 9Y6792 GASKET-SPARK
12 2037859 GASKET
48 3165978 ROTOCOIL AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 35% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

*******Group 3*******
20 9Y6792 GASKET-SPARK
20 2037859 GASKET
80 3165978 ROTOCOIL AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 35% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.


ACTION REQUIRED

****Parts Stock ****

1. Inspect the dealer parts stock to determine if any 10R4565, 10R4703, 10R7927, 10R7928, 4155584, 4155585 Heads have a packaging date code between 17 June 2013 (D17M06Y13) and 10 December 2013 (D10M12Y13). If the packaging date code label falls between these dates, the box must be opened and the rotocoils must be inspected to determine if they are incorrect. Refer to Image 1.1.1 and Image 1.2.1 in the Rework Procedure.

2. For those affected heads in dealer parts stock with the incorrect 332-7386 Rotocoils installed, repair the head to replace the rotocoils with the correct 316-5978 Rotocoils and return to dealer parts stock.

 
 
****Affected Product****
Replace the existing 332-7386 Rotators with new 316-5978 Rotators. Refer to the attached Rework Procedure.

OWNER NOTIFICATION

Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

****Parts Stock****

Submit one claim for all 10R4565, 10R4703, 10R7927, 10R7928, 4155584, 4155585 heads that were reworked in dealer parts stock. 0.5 hours of labor will be allowed for each cylinder head reworked in dealer parts stock. 4 - 332-7386 rotocoils will be allowed for each cylinder head reworked in dealer parts stock.

 
 
****Affected Product****
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
100%
100%
0%
0%
0%
0%
 NOTE: This is a 18.0-hour job for Group 1

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
100%
100%
0%
0%
0%
0%
 NOTE: This is a 13.5-hour job for Group 2

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
100%
100%
0%
0%
0%
0%

 NOTE: This is a 22.5-hour job for Group 3


PARTS DISPOSITION

****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty
parts handling.

 
EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CYLINDER HEADS

MODELS INVOLVED - CERTAIN G3512C, G3512E, G3516C, G3520C, AND G3520E ENGINES

Dear Cat Product Owner:


The 316-5978 Rotocoil needs to be replaced on the products listed below. The existing 332-7386 Rotocoil can lose the ability to rotate. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product, please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 04Apr2014 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.



Caterpillar Inc.

Identification #(s)



Attached to 04Apr2014 Service Letter


Rework Procedure


 
Image1.1.1: This picture shows a good 316-5978 Rotocoil without tabs showing.
Image1.1.1
 
Image1.2.1: This picture shows a rotocoil with tabs that will need to be replaced with 316-5978 Rotocoil.
Image1.2.1
 
If a rework tool is needed, fabricate the tool. Refer to Image1.3.1, Image1.3.2, Image1.3.3, and Image1.3.4.
Image1.3.1
Image1.3.2
Image1.3.3
Image1.3.4
 
Rework Procedure:

1. Bring cylinder to Top Dead Center

2. Remove transformer and wiring

3. Remove rocker cover

4. Remove rocker arms and shafts

5. Remove rocker box and bridges

6. Remove pushrods

7. Remove spark plug

8. Place valve spring compression tool on top of all four valves centered over the spark plug hole.
Image1.4.1
Image1.4.2
 
9. Align positioning bolt (1), (2), with the lower rocker box bolt on the top left and the bridge bolt on the bottom right. Tighten these bolts unit lightly seated.

10. Ensure that the center of the tool is aligned above the spark plug hole and carefully thread main jackscrew into place (3). Be cautious not to damage spark plug threads. Stop tightening once the top of the jackscrew in 10cm from the top of the plate.
Image1.5.1
Image1.5.2
 
11. With jackscrew (3) tightened into spark plug hole. While holding jackscrew with 9/16 wrench (4), Tighten 1 1/8 nut (5) to compress the valve springs.
Image1.6.1
 
12. Continue compressing valve springs until stand offs on tool are seated against head (6). DO NOT TIGHTEN ANY FURTHER; SPARK PLUG ADAPTER DAMAGE COULD RESULT.
Image1.7.1
 
13. Valve stems and keepers should now be accessible. Use magnet to remove 2 keepers from each valve stem. (7)
Image1.8.1
Image1.8.2
 
14. Once all keepers are removed, start to loosen 1 1/8 nut, (5) while holding jackscrew with 9/16 wrench (4), to relieve the pressure from the springs.

15. Nut (5) should be completely loose then the positioning bolts (1 and 2) can be removed and plate can be taken off.

16. Remove old rotators and install new rotators.

17. Repeat steps 7-12 to reinstall the keepers.

18. Once keepers are in place, start to loosen 1 1/8 nut, (5) while holding jackscrew with 9/16 wrench (4), to relieve the pressure from the springs. Ensure keepers stay in groove while loosening.

19. Nut (5) should be completely loose then the positioning bolts (1 and 2) can be removed and plate can be removed.

20. Reinstall spark plug with new 9Y-6792 Gasket.

21. Reinstall rocker box with new 296-5820 Gasket

22. Reinstall pushrods

23. Reinstall valve bridges and adjust

24. Reinstall rocker arms and adjust

25. Mount rocker box

26. Reinstall transformer and wiring

27. Move next cylinder to TDC and start procedure over again until all 332-7386 Rotators have been replaced with 316-5978 Rotators.
 
 

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