Product Support Program For Repairing Valve Failures On Certain 3606, 3608, 3612, And 3616 Engines Equipped With Remanufactured Cylinder Head(s) Caterpillar

Product Support Program For Repairing Valve Failures On Certain 3606, 3608, 3612, And 3616 Engines Equipped With Remanufactured Cylinder Head(s)

August 18, 1992
U-118
A-88
AU-78
E-73
O-93
TM-13

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 Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4793" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description code.

NOTE: Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible. Removal of heads from engines for inspection prior to failure is not covered unless authorized in writing by the local Caterpillar District Office.

Termination Date

Problem

The valves on certain 3606, 3608, 3612, and 3616 Engines equipped with an 0R2756, 0R2757, 0R2869, 0R3227, 0R3228, or 0R3250 Remanufactured Cylinder Head Group may fail if the valve seat "TIR" or the valve guide "ID" are not to the correct specifications.

Affected Product
Model & Identification Number

3606^* (8RB1-Up; 2S18451)

3608^* (6MC1-Up)

3612^* (9RC1-Up; 2S18175)

3616^* (1PD1-Up)

Parts Needed

0R3227 Cylinder Head Group (Use as required)

or

0R3228 Cylinder Head Group (Use as required)

or

0R3250 Cylinder Head Group (Use as required)

Action Required

Parts Stock

Inspect all of the remanufactured cylinder heads listed below that are in either dealer or customer parts stock if they have a date code prior to March 1992.

0R2756 Cylinder Head Group

0R2757 Cylinder Head Group

0R2869 Cylinder Head Group

0R3227 Cylinder Head Group

0R3228 Cylinder Head Group

0R3250 Cylinder Head Group

The date code format for these remanufactured cylinder heads is

where the codes for the numbers of the months and years are as follows:

Example: The date code for march 1992 is "NEDM".

The date code is stamped near the remanufactured part number on the head casting. Cylinder Heads with an "A", "B", or "G" stamped near the date code have already been reworked and need no further action.

Cylinder heads with a date code prior to March 1992 that do not have an "A" "B", or "G" stamped near the date code need to be disassembled and inspected to make sure that the valve seat "TIR" is correct and that the valve guide "ID" is correct.

Use the "Guideline For Reusable Parts", Form SEBF8129 as a reference for the procedure to measure the valve seat "TIR" Do not use the specifications provided in the guideline. They are in the process of being changed. The correct maximum valve seat "TIR" is 0.15 mm (.006").

When inspecting valve guides be very careful to check the inside diameter of the installed valve guide completely through the valve guide. If a gauge is needed before the release of a new tool group containing a new long plug gauge, dealers can have one made locally. The gauge must have a diameter of 16.003 +0.005 -0.000 mm (.6300 +.002 -.000") and measure 200 mm (7.9") long. Passing this guage all the way through the complete length of the installed valve guide will ensure that no area is below the minimum diameter, and also provide a good check of guide inside diameter straightness.

If a cylinder head conforms to the information provided above, or if the cylinder head is reworked to ensure it conforms to the information above, stamp a letter "C" near the date code, and return the head to your parts stock.

If the cylinder head does not conform to the information above, and you choose not to rework it, refer to the Parts Disposition.

Affected Product

Replace any remanufactured cylinder head described under Parts Stock that was installed on an engine if it has had a valve failure due to valve face guttering or due to a valve stem seizure.

Service Claim Allowances

Parts Stock

Two hours of labor will be allowed for each remanufactured cylinder head removed from parts stock that is disassembled and inspected.

One additional hour of labor will be allowed for each remanufactured cylinder head that is reworked and returned to parts stock.

Affected Product

NOTE: This is a 6-hour job.

NOTE: If the cylinder head(s) were removed from the engine for inspection prior to failure, retain a copy of the written authorization from the Caterpillar District Office for audit purposes.

Parts Disposition

Parts Stock - COSA Dealers

Return all cylinder heads that are removed from parts stock to:

A Core Credit Request - Packing List (CCR-PL) No. 01-084927-06 (former) or 01-89514-00 (new) form needs to be included with the returned head. Reference to the warranty claim number must be made on the form. Mark an "X" in the area provided where it shows Warranty Credit (former form only).

Grimbergen will reimburse the core credit. Your warranty claim for the inspection labor and dealer net value of the Remanufactured unused head will be reimbursed through the standard warranty channel.

Parts Stock - All Other Dealers

Return all cylinder heads that are removed from parts stock and a copy of the claim to:

Affected Product

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