PRODUCT SUPPORT PROGRAM FOR REPAIRING AN OUTER VALVE SPRING FAILURE ON VARIOUS 3508, 3512, 3516, AND 3524 MACHINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING AN OUTER VALVE SPRING FAILURE ON VARIOUS 3508, 3512, 3516, AND 3524 MACHINE ENGINES

Usage:

REBE2397-03

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27Nov2007

(Revised 11Nov2008)

U-614

A-500

D-501

O-536

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPAIRING AN OUTER VALVE SPRING FAILURE ON VARIOUS 3508, 3512, 3516, AND 3524 MACHINE ENGINES
1108 1100		PS51400

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51400" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 27Nov2007 (Revised 23May2008) Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

30Nov2009

PROBLEM

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The existing outer valve spring can fail on various 3508, 3512, 3516, and 3524 machine engines.

AFFECTED PRODUCT

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Model	Identification Number
777B	4YC75061-75069, 75071-75074, 76001-76004
777C	4XJ00759, 798-1123, 75001-75006 8JL00038-00085
777D	3PR00078-01126, 75001-75005, 75007-75008 6XZ00077-00106 AGC00077-00569, 700-2547 DCB00077-00278, 32223 FKR00200-00278, 282-284
777DHA	2YW00077-00105 AGY00077-00080
785	8GB78001-78003, 78005-78006
785B	6HK00462-00987, 75001-75005, 75007, 76001-76003, 78001-78006
785C	1HW00085-00134 APX00160-01487
785C HA	5AZ00085-00114, 264-273, 400-425
789B	7EK00335-00688, 60477, 75001-75002
789C	2BW00089-00160, 303-348, 500-1383
793	3SJ00006-00056, 798, 75001
793B	1HL00012-00524, 75001-75003, 76001-76005, 78001-78007
793C	4AR00076-00424, 76006-76009, 77002 4GZ00001, 13, 93-264 ATY00183-00263, 400-1124 CBR00093-00108
793D	FDB00105-00582
797	5YW00193-00277
797B	JSM00123-00298
992G	7HR00034-00387, 75001, 75003, 75006-75014 ADZ00127-00257, 300-623, 75001-75002 AZX00297-00839
994	9YF00006-00227, 75001-75002
994D	3TZ00251-00336, 380
994F	44200149-00240
CIPI	KCH22001-22038
D11N	4HK00561-00635, 75001-75007, 78001 74Z05277, 75264-75278, 75280, 75282-75290, 75293-75300, 75727, 77001
D11R	7PZ00002, 286-1705, 75001-75009 8ZR00297-00471, 75001-75005 9TR00197-00473, 75002
D11R CD	9XR00149-00189, 75001 AAF00132-00290, 75001

PARTS NEEDED

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Qty	Part Number	Description
4	2A4429	LOCK-RETAINER
4	1977055	LOCK-RETAINER
4	3165976	SPRING
4	3165977	SPRING-VALVE
2	3165978	ROTOCOIL AS
2	3165979	ROTOCOIL AS
2	3165980	SEAL
2	3165981	WASHER
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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

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If a broken outer valve spring is found before an engine failure it should be replaced with the cylinder head on the engine after inspecting the top end and determining no other damage has occurred. This can be done by bringing the piston to top dead center and removing the rotator and keepers. Pressurizing the cylinder may be required. A new rotator and new keepers should be used when reassembling.

Refer to appropriate Service Manual as required.

NOTE: If the valve has made piston contact the cylinder pack and cylinder head should be replaced.

If the failure requires the engine to be removed from the chassis, the Caterpillar local service representative must be contacted to determine proration for life received.

The following is to serve as guidance for the support of catastrophic failures of 3500 series product as a direct result of a valve spring failure.

The aim is to support the replacement of items that do not typically get replaced during a dealer rebuild. The additional support will be limited to the Engine Block and crankshaft which are likely to be damaged beyond reuse and salvage guidelines in the event of a catastrophic failure.

Component Life Block / Crank Parts cost Pro-ration guidance for Service Representatives:
1st Life 100% D/N
2nd Life 66% D/N
3rd Life 33% D/N

The determination of acceptable life should be agreed to by the service rep and dealer. Achieved life is to be based on the O&MM overhaul hours.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-10000 hrs, 0-18 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-15000 hrs, 19-36 mo	67.0%	67.0%	0.0%	0.0%	25.0%	33.0%
15001-18000 hrs, 37-54 mo	33.0%	33.0%	0.0%	0.0%	50.0%	67.0%