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

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

Usage:

REBE4614-00

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04Dec2008

U-622

A-515

D-529

O-567

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPAIRING AN OUTER VALVE SPRING FAILURE ON VARIOUS 3508, 3512, AND 3516 PETROLEUM ENGINES
1100 1108		PS51601

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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 "PS51601" 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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TERMINATION DATE

31Dec2010

PROBLEM

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

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3508	68Z01256-01261, 1266-1270, 1275-1278, 1286, 1288-1290, 1299-1311, 1322-1324, 1326-1339, 1341-1351, 1353-1356 70Z01079-01081
3508B	2HW00248-00378, 382-383 3DW00175-00179, 186-190 BGX00147-00150 CBB00190-00575 S2A00127 S2D00139, 158, 213-215, 217-219
3508C	LLC00100-00176, 181-185, 188 LLE00101-00195, 197-257, 259-289, 295-330, 332, 334-335, 338-352, 356-359, 361-370, 372, 374, 376, 378, 380-393, 395-401, 403-404, 406, 408, 410, 412-413, 418, 421-423, 429, 431, 436, 442-443, 445-447, 452-453, 457-458, 461-463, 465-468, 470, 472-473, 479

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*****Group 2*****
3508	23Z07947, 7961, 7972, 7978, 7986, 7993, 8005-8007, 8009-8011, 8024-8025 5PW00862-00866 95Y01216, 1220-1230, 1232, 1236-1237, 1239-1240, 1243-1244, 1254-1255, 1259-1264, 1266-1267, 1273-1277, 1281-1283, 1291-1292, 1299-1302, 1304-1315, 1326, 1331-1333, 1338, 1340-1343, 1348 96Y02155 97Y00754, 757 CNF00465-00468, 470-477, 541, 736, 738

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*******Group 3*******

3508B

3DM00465, 478, 486-487, 491, 493-494, 497-500, 506-507, 510-523, 527-529, 532-535, 538-540, 543

5KW01448, 1452-1453, 1617, 1629, 1636, 1704, 1793, 1811, 1923, 1962

6PN00970-00972

BPX00114

CNB00892, 977, 1436, 1517, 1533, 1580, 1704-1705

S2B00134, 144, 151, 172-173, 177, 238, 254, 290-292, 305, 320-321, 324, 363, 365, 369, 383, 394, 414, 427, 431-432, 442, 447, 452, 462-464, 468-469, 473, 479, 483, 485, 545-546, 548, 550-551, 562-563

ZAD00199-00200, 245, 250, 277-278, 305, 320-322, 333-335

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*****Group 4*****
3512	65Z01130, 1132-1147, 1153-1176, 1178-1216, 1221, 1224-1225, 1231-1279, 1281-1282, 1287-1303, 1306-1320, 1323-1329, 1332-1333, 1336-1338, 1340-1348, 1354-1355, 1357-1359, 1364-1366, 1369-1371, 1375-1376, 1384-1385, 1405-1407 67Z02050-02058, 2060-2067, 2069-2096, 2101-2102, 2104-2108, 2110-2116, 2118-2119, 2125-2160, 2163-2168, 2173-2189, 2191, 2196-2199, 2204-2206, 2210, 2212-2217, 2219, 2225-2226, 2229-2232, 2241, 2243-2246 PTG00177-00196, 201-269, 274-288, 291-296, 298, 307-314, 319-330, 332-333
3512B	1PW00428, 431-448, 450-455 2GW00429-00430 4AW00816-01638, 1642-1709, 1719, 1722-1727, 1731-1732, 1742-1745 BLF00162, 165, 169, 171, 176-178, 185, 188, 190 PTF00131-00175, 181-184, 196-272, 274-287, 291-310, 315-324, 326-327, 329-332, 334, 340-358, 360-366, 369-382, 391-402, 404-406, 411, 413-415, 417-418, 420, 431-434, 439-440, 443-444, 447-448, 450-459, 461-463, 481-491, 498-499, 502, 504 S2G00100, 103-107, 111, 116, 121-122, 124-134, 137, 140-143, 149-151, 154-156, 162-165, 167-169 S2K00180-00182 S2N00116
3512C	LLA00100-00484, 487-545, 547-739, 742-786, 788, 790-792, 794-854, 856-920, 922-972, 974-1004, 1007-1024, 1028-1039, 1041, 1043-1044, 1047-1070, 1072-1075, 1077-1081, 1083-1086, 1088-1127, 1129-1136, 1138-1141, 1143-1150, 1152-1155, 1158, 1162, 1166-1167, 1172, 1175-1176, 1179-1182, 1190-1194, 1207-1212, 1216-1217, 1223, 1227, 1230, 1234-1236, 1241-1242, 1244-1245, 1251, 1253, 1258-1259, 1261-1262 LLF00100-00182, 189-190, 204-206, 208-209, 212-244, 247, 252-265, 268-270 RMS00150-00179, 181-193, 195-214, 216-219, 221-226

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*****Group 5*****
3512	24Z10153-10154, 10158, 10164, 10172, 10176, 10195, 10197, 10213-10215, 10242, 10247-10249 49Y01033-01034, 1037-1046, 1048, 1050-1052, 1063-1069, 1076-1080, 1082-1087, 1094-1095, 1099-1110, 1114, 1116-1122, 1125, 1127, 1132, 1134-1135 50Y01849-01850 51Y00862 6WW00667, 713, 717, 728, 1098, 1307 CMJ00716-00720, 798, 806-808, 812-813, 949-950, 1032, 1076, 1078-1080, 1088, 1278, 1301, 1335, 1506, 1557, 1585, 1687, 1695, 1707, 1747, 1753 PTH00249-00285, 290-431, 434-488, 493-503, 506-509, 511-543, 546-548, 550-552, 554-571, 575-589, 591, 593-608, 614-632, 634-649, 656-659, 664-671, 683 SBG00338 ZAF00215, 225, 239-240, 243, 248-252, 254-255, 257-258, 290-291, 297-298, 362-363
PM3512	BRF00283-00286

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*******Group 6*******

3512B

6GW01341, 1355, 1375, 1398, 1503, 1508, 1517, 1528

8EM00509-00512, 514, 527-531, 538-548, 551, 554-556, 559-561

8RM00758, 824-825, 827, 852

BRK00243, 284-285, 336-337

CMC00889, 936-939, 1082-1084, 1087, 1150-1152, 1154-1156, 1160, 1494, 1668, 1762-1763, 1867

FDE00317-00318, 423, 425

MHA00100-00135

PTM00260-00287, 289-706, 710-958, 960-962, 964-968, 970-1082, 1084-1099, 1102-1108, 1111-1130, 1132, 1134-1136, 1138-1144, 1146-1149, 1151-1154, 1156-1159, 1161-1186, 1188, 1190-1191, 1202-1208, 1216-1219, 1221-1225, 1227-1229, 1232-1233, 1239-1241, 1243, 1245, 1251-1252, 1261-1262, 1266, 1276-1277, 1292-1293, 1296-1298, 1300, 1305, 1318

S2H00126, 138-139, 142-143, 150, 156, 161-163, 171, 188, 190, 195, 197-198, 201, 208, 218, 221-223, 225, 233, 237-242, 244, 247-249, 260, 264-268, 278, 281, 292-293, 296-303, 310, 326, 344, 376, 379-382, 384

S2J00334

S2L00548-00549

ZAH00291, 319-320, 440, 443, 507, 523, 600, 640

ZAJ00140-00143

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*****Group 7*****
3512B	2AF00364-00707, 711-712
SPF343	6RZ00429-00510

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*****Group 8*****
3512C	R1A00101, 103-167, 169-171, 173-201, 203-301, 303-304
SPF343C	RTX00100-00221, 223

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*****Group 9*****
3516	71Z00404-00405, 409-410, 412-416, 421-430, 432 73Z00968-00971, 976-979 PTD00270-00285, 288, 290, 294-301, 305-306
3516B	1NW00145-00157 2FW00334-00348, 353-357, 366-411, 413-422 CBN00312-00498 GZT00122-00126 GZX00112 LEK00112-00124, 131-138, 142-144, 147-150 RKT00116-00132 S2P00104, 108-138 S2W00106
3516B HD	S2Z00100-00129, 132-153, 164-209, 212, 217-224, 227-228, 234-237, 246-250, 252, 254, 257-259, 261-267, 269-273, 275-276, 280
3516C	PES00200-00223 SBK00339-00400, 428
PM3516B	BPD01131, 1198-1199

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*****Group 10*****
3516	25Z07100-07101, 7105, 7114, 7116, 7118-7119 27Z00853-00857, 859-863, 865-866, 875-878, 884-887, 889-893, 895-896, 901, 903, 906, 915, 917-918 29Z01453-01456 8TW00463 GZR00133, 135-136 ZAL00170-00171, 174

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*******Group 11*******

3516B

2JW00416

7RN01957, 1990

8NW00996

9AN00358-00366, 370-373, 388-389, 391-400, 402-403, 407-408

CAN00133-00134

FDX00380-00381, 415

GAR00189-00190

GZS00153, 158, 223, 226, 239, 242, 244, 725, 737

PAG00126, 171, 198-199

PBR00156-00160, 167

S2R00134, 137, 144-146, 166, 187-192, 196, 216, 250-252, 254, 256-260, 268, 271-272, 274-281, 284-292, 296, 301, 308-309, 311-312, 324, 338-343, 368, 370-374, 378, 380, 389-391, 396, 398-400, 403, 406-407, 413-414, 421, 423, 427, 431, 436-440, 443-446, 451-452, 485, 507

S2S00291-00294

ZAP00145, 242, 583-584, 606, 742, 773

ZAR00148, 346-347

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
32	2A4429	LOCK-RETAINER
32	1977055	LOCK-RETAINER
32	3165976	SPRING
32	3165977	SPRING-VALVE
16	3165978	ROTOCOIL AS
16	3165979	ROTOCOIL AS
16	3165980	SEAL
16	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.
*****Group 2*****
8	10R2003	HEAD GP-CYL BSC
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.
*****Group 3*****
8	10R7765	HEAD GP-CYL
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.
*****Group 4*****
48	2A4429	LOCK-RETAINER
48	1977055	LOCK-RETAINER
48	3165976	SPRING
48	3165977	SPRING-VALVE
24	3165978	ROTOCOIL AS
24	3165979	ROTOCOIL AS
24	3165980	SEAL
24	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.
*****Group 5*****
12	10R2003	HEAD GP-CYL BSC
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.
*****Group 6*****
12	10R7765	HEAD GP-CYL
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.
*****Group 7*****
12	10R7765	HEAD GP-CYL
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.
*****Group 8*****
48	2A4429	LOCK-RETAINER
48	1977055	LOCK-RETAINER
48	3165976	SPRING
48	3165977	SPRING-VALVE
24	3165978	ROTOCOIL AS
24	3165979	ROTOCOIL AS
24	3165980	SEAL
24	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.
*****Group 9*****
64	2A4429	LOCK-RETAINER
64	1977055	LOCK-RETAINER
64	3165976	SPRING
64	3165977	SPRING-VALVE
32	3165978	ROTOCOIL AS
32	3165979	ROTOCOIL AS
32	3165980	SEAL
32	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.
*****Group 10*****
16	10R2003	HEAD GP-CYL BSC
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.
*****Group 11*****
16	10R7765	HEAD GP-CYL
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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There are two different repair actions in this program depending if there is a remanufactured cylinder head available for the engine. The Affected Product and associated Parts Needed have been divided into groups specific to the repair.

No Remanufactured Cylinder Head Available:
If a broken outer valve spring is found, all of the valve spring packs on the engine should be replaced. This action can be done without removing the cylinder heads from the engine by bringing the piston to top dead center and removing the rotator and keepers. Pressurizing the cylinder may be required. New inner and outer springs, rotators, exhaust valve spring washers, inlet valve stem seals and keepers should be used when reassembling.

Remanufactured Cylinder Head Available:
For engines with a remanufactured cylinder head available, replace the existing cylinder head on each cylinder with a remanufactured cylinder head. This work should be completed only after inspecting the top end and determining no other engine damage has occurred.

Refer to appropriate Service Manual as required.

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

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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%
*****Group 1*****
0-11000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 30.0-hour job for Group 1

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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%
*****Group 2*****
0-9000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 30.0-hour job for Group 2

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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%
*****Group 3*****
0-9000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 30.0-hour job for Group 3

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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%
*****Group 4*****
0-11000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 40.0-hour job for Group 4

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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%
*****Group 5*****
0-9000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 40.0-hour job for Group 5

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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%
*****Group 6*****
0-9000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 40.0-hour job for Group 6

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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%
*****Group 7*****
0-4000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 40.0-hour job for Group 7

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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%
*****Group 8*****
0-4000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 40.0-hour job for Group 8

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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%
*****Group 9*****
0-11000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 50.0-hour job for Group 9

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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%
*****Group 10*****
0-9000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 50.0-hour job for Group 10

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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%
*****Group 11*****
0-9000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%