PRODUCT SUPPORT PROGRAM FOR INSPECTING, REPLACING OR REPAIRING 10R-1495 REMANUFACTURED CYLINDER HEADS ON CERTAIN G3606, G3608, G3612, AND G3616 ENGINES Caterpillar
PRODUCT SUPPORT PROGRAM FOR INSPECTING, REPLACING OR REPAIRING 10R-1495 REMANUFACTURED CYLINDER HEADS ON CERTAIN G3606, G3608, G3612, AND G3616 ENGINES
Usage:
REBE7127-02
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31May2011
(Revised 24Jan2012)
U-219
A-180
D-202
O-198
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Before/After
Parts stock action needed
PRODUCT SUPPORT PROGRAM FOR INSPECTING, REPLACING OR REPAIRING 10R-1495 REMANUFACTURED CYLINDER HEADS ON CERTAIN G3606, G3608, G3612, AND G3616 ENGINES
7750
PS43297
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NOTE:
This Program must be administered either before or after failure.
In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43297" as the Part Number
and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.
If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
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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,
"7755" as the Group Number, "56" as the Description Code.
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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.
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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 31May2011 (Revised 08Sep2011) Service Letter. Changes have been made to the Service Claim Allowances.
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TERMINATION DATE
31May2013
PROBLEM
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Certain remanufactured cylinder heads used on G3600 engines were assembled incorrectly from the factory. Inlet valves were installed into the exhaust ports and exhaust valves were installed into the inlet ports. The cylinder heads with packaging date codes between 11 February 2011 (D11M02Y11) and 15 April 2011 (D15M04Y11) may contain these affected heads.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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****Parts Stock ****
1. Inspect dealer inventory to determine if any 10R-1495 heads have a packaging date code between 11 February 2011 (D11M02Y11) and 15 April 2011 (D15M04Y11). If the packaging date code label falls between these dates, the box must be opened and the valves must be inspected for the correct location on the head.
2. For those affected heads with the incorrect orientation in inventory, repair the head to the correct valve orientation per SENR3954 and return to inventory.
3. Review the sales records to determine if any customer has purchased a 10R1495 Head within the date code range for use on their engines.
****Affected Product****
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1. Inspect dealer service records that apply to the affected G3600 engine product and determine if 10R1495 heads used for service replacement beginning 11 February 2011 to 20 May 2011.
2. For G3600 engines in dealer territories that have received new 10R1495 heads installed within the affected dates, dealers must inspect those heads that were installed on the affected engines. This can be done by removing the rocker box covers and rocker shafts to inspect the valve tips to verify the correct valve orientation. The intake valves have 3 grooves machined near the tops. The exhaust valves do not have grooves machined in them. The part numbers of the valves are etched on the valve tips. Refer to SENR3954 for correct orientation.
3. Replace affected heads on the engines with new 10R1495 heads.
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SERVICE CLAIM ALLOWANCES
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****Parts Stock****
Submit one claim for all 10R1495 cylinder heads that were reworked in dealer parts stock. 2.0 hours of labor will be allowed for each cylinder head rework.
****Affected Product****
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-80000 hrs, 0-96 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 0.5-hour job for Group 1
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
This is a 0.5 hour job to inspect dealer service records to determine if further engine inspection is needed.
If needed up to 2.0 hours per engine will be allowed to remove rocker box covers to inspect the valve orientation of the heads.
If needed, an addtional 10.0 hours per head will be allowed to replace heads with valves incorrectly installed.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-80000 hrs, 0-96 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 0.5-hour job for Group 2
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
This is a 0.5 hour job to inspect dealer service records to determine if further engine inspection is needed.
If needed up to 2.0 hours per engine will be allowed to remove rocker box covers to inspect the valve orientation of the heads.
If needed, an addtional 10.0 hours per head will be allowed to replace heads with valves incorrectly installed.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-80000 hrs, 0-96 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 0.5-hour job for Group 3
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
This is a 0.5 hour job to inspect dealer service records to determine if further engine inspection is needed.
If needed up to 2.0 hours per engine will be allowed to remove rocker box covers to inspect the valve orientation of the heads.
If needed, an addtional 10.0 hours per head will be allowed to replace heads with valves incorrectly installed.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 4*******
0-80000 hrs, 0-96 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 0.5-hour job for Group 4
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
This is a 0.5 hour job to inspect dealer service records to determine if further engine inspection is needed.
If needed up to 2.0 hours per engine will be allowed to remove rocker box covers to inspect the valve orientation of the heads.
If needed, an addtional 10.0 hours per head will be allowed to replace heads with valves incorrectly installed.
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.
