PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD LIFTING EYE BOLT HOLE ON VARIOUS 3508, 3512, AND 3516 ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD LIFTING EYE BOLT HOLE ON VARIOUS 3508, 3512, AND 3516 ENGINES

Usage:

REBE4698-00

Show/hide table

19Dec2008

U-657

A-545

D-559

O-599

Show/hide table

*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD LIFTING EYE BOLT HOLE ON VARIOUS 3508, 3512, AND 3516 ENGINES
1100 1101		PI31606

Show/hide table

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31606" 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 "PI31606" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table

COMPLETION DATE	TERMINATION DATE
30Jun2009	31Dec2009

PROBLEM

Show/hide table

One of the cylinder head lifting eye bolt holes needs to be inspected on various 3508, 3512, and 3516 engines. The affected cylinder head castings were poured using a certain pattern with a potential shift in the water passage core. This condition could result in penetration of the water jacket passage at this drilled hole location creating a coolant leak path into the rocker box and a subsequent oil dilution problem.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
3508B	2GR08257-08266, 8268
3512	4WJ01367
3512B	8BR02190, 2192, 2198, 2201, 2213
3516	54Z01211
3516B	7TR02436, 2439, 2449, 2454-2455, 2464 8WM02002, 2023, 2029, 2036, 2047, 2049-2051, 2056-2057, 2074, 2080
3524B	3TN00832, 835, 840, 842, 848
785C	APX01583, 1585-1587, 1589-1613, 1622
785D	MSY00071-00073
789C	2BW01438-01449, 1451-1462
793D	FDB00954, 958-1007, 1010, 1017, 1019, 1022
797B	JSM00411-00422

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
20	0102591	SETSCREW-SOCKET
1	2425328	HEAD AS-CYL (AS REQUIRED)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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

Show/hide table

Ensure the following items are included in the service technician's tool kit:
1. Brake cleaner
2. 3/16" Tee handle allen wrench
3. Blow gun with extension
4. Red Loctite-271 (CAT Part Number 155-0695)
5. Syringe with 1/8" tubing (as a suggested way of getting the right amount of loctite into the lifting eye hole)

Refer to the attached Rework Procedure for pictures and more details.

Show/hide table

OWNER NOTIFICATION

Show/hide table

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

Show/hide table

Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

Show/hide table

NOTE: This is a 1.0-hour job
An additional 1 hour will be allowed per head if the Rocker box needs to be removed. An additional 4 hours will be allowed per head if the cylinder head needs to be replaced due to an observed coolant leak.

Show/hide table

PARTS DISPOSITION

Show/hide table

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Show/hide table

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD LIFTING EYE BOLT HOLE ON VARIOUS 3508, 3512, AND 3516 ENGINES

MODELS INVOLVED - 3508, 3512, AND 3516 MODEL ENGINES

Dear Caterpillar Product Owner:

Certain identifiable cylinder heads need to be reworked on the products listed below. The existing cylinder head may leak and the proposed rework will replace any cylinder heads showing signs of a
coolant leak while proactively plugging the lifting eye hole that may potentially leak in the future. This procedure will in no way affect the performance and serviceability of your product. You will not be charged for the service performed.

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

Please refer the dealer to their Service Letter dated 19Dec2008 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 19Dec2008 Service Letter

Rework Procedure

Show/hide table

The cylinder heads affected by this issue can be identified by 3 raised dots located near the outboard machined rail of the head (See image 1.1.1 & 1.1.2)

NOTE: Some dots may be round and easy to see while other may be less pronounced (see images 1.1.3)

Image1.1.1

Image1.1.2

Image1.1.3

If these dots are observed on any of the heads on the engine, follow the steps detailed below for each of the affected cylinder heads.

1. Remove the valve cover and look for signs of coolant buildup on the top of the cylinder head within the rocker box.

2. Check for oil emulsion (coolant traces in the oil) in the drilled 3/8-inch left hand side lifting eye hole that is located 38.10 mm (1.50 inch) left of the injector bore (See Image 1.2.1). If there are any signs of emulsion, the head will need to be replaced. If there is no sign of emulsion, proceed to next step.

Image1.2.1

3. Remove oil from the above mentioned bolt hole with a blow gun.

4. Fill bolt hole with brake cleaner.

5. Blow out hole with blow gun until hole is dry.

6. Look for signs of coolant seeping into the hole. If coolant starts to seep into the hole, replace the head; if bolt hole remains dry, proceed to the next step.

7. Carefully Place approximately 0.75 mL (cc) of Red Loctite-271 in the bottom of the bolt hole. A syringe with 1/8-inch tubing attached is a suggested method of getting the loctite into the hole (see image 1.3.1).

8. Insert the set screw into the bottom end of the 3/16-inch T-handle allen wrench (see image 1.3.1)and then insert the set screw into the left hand side lifting eye hole. Torque set screw to 40N-m (30ft-lbs). A small piece of paper towel on the end of the allen wrench may help secure the set screw (See image 1.3.2).

Image1.3.1

Image1.3.2

Note: In certain instances the set screw may not engage the bolt hole threads because of the proximity of the rocker box covering a small portion of the hole. If this situation occurs, the rocker box will need to be removed in order to install the set screw. Refer to the 3500 Disassembly and Assembly Guide for removal and installation instructions.

10. Re-install valve cover.

11. Torque valve cover bolts to 27 N-m (20 lbf-ft).