PRODUCT SUPPORT PROGRAM FOR REWORKING THE INLET VALVES THAT MAY FAIL PREMATURELY ON CERTAIN 3116 MARINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE INLET VALVES THAT MAY FAIL PREMATURELY ON CERTAIN 3116 MARINE ENGINES

Usage:

SEBE7042-04

October 18, 1999
(Revised January 2003)
U-290
A-225
AU-184
S-157
H-114
O-247
TM-5

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE INLET VALVES THAT MAY FAIL PREMATURELY ON CERTAIN 3116 MARINE ENGINES
1105		PS5711

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 "PS5711" 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.

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 Revised Service Letter replaces the October 18, 1999 (Revised November 2001) Service Letter. Changes have been made to the Termination Date.

TERMINATION DATE

October 31, 2003

PROBLEM

The inlet valve may fail prematurely on certain 3116 Marine Engines. NOTE: This program is not intended to cover engine replacements. If a valve failure causes an engine replacement, the engine should be replaced under normal warranty or goodwill if needed.

AFFECTED PRODUCT

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Model	Identification Number
3116	4KG6600-8400 1SK2000-2248
NOTE: The serial number of the sister engine in the same boat may also be affected. If the PIN on the sister engine is below 4KG8400 or 1SK2248, perform this rework on that engine before failure.

PARTS NEEDED

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Quantity	Part Number	Description
1	7C1159	Gasket
1	7C7613	Gasket ? Outlet
3	3D2824	Seal ? O-Ring
1	7E0844	Seal
1	4F7391	Seal ? O-Ring
1	6F6673	Seal ? O-Ring
1	3J1907	Seal ? O-Ring
1	9M4849	Seal ? O-Ring
1	4P7704	Gasket ? Turbocharger
1	1S7057	Gasket
2	8T0280	Seal ? O-Ring
1	6V8397	Seal ? O-Ring
1	2W7212	Gasket ? Regulator
1	7W2398	Gasket
1	1077832	Gasket
3	1136200	Gasket
1	1136250	Gasket
6	1148718	Seal ? O-Ring
1	1169924	Filter Assembly ? Oil
1	1192940	Gasket
12	1193036	Seal ? Valve Stem
6	1577125	Valve ? Inlet
6	1577126	Valve ? Exhaust

ACTION REQUIRED

See the attached Rework procedure.

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar			Dealer Suggested			Customer Suggested
	Parts (D/N)	Labor Hrs (Cost)		Parts	Labor Hrs		Parts (C/L)	Labor Hrs (Sell)
Unlimited	100%	36.6		0	0		0	0
NOTE: This is a 36.6-hour job.
NOTE: The age and hours for this program are unlimited. All labor at sell rate and parts at customer list are reimbursed 100% by Caterpillar.
Labor Hour Breakdown (In Boat Repair)
SMCS code			Hours			Description
1100-010			3.0			R & I Hatches
1100-001			24.0			R & I Cylinder Head*
1100-010			2.6			Repair Cylinder Head
1100-010			1 (each engine)			Paint Parts
1100-010			1 (each engine)			Clean Boat
1100-010			1 (each engine)			Test After Repair
1100-010			4.0			Travel Time

* 9 hours to R & I Cylinder Head in shop

PARTS DISPOSITION

NOTE: In North America, as a condition of payment for this Product Support Program, the replaced inlet valves (with the valves clearly numbered as to which cylinder and engine they came from) must be returned to the following address:

CATERPILLAR INC.

8201 N. UNIVERSITY-DOCK 22

PEORIA, IL 61615

ATTENTION: SETH STUDNICKA

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

Attach. (1-Rework Procedure)

REWORK PROCEDURE

1. Drain oil and coolant.

2. Inspect for loose rivet at governor link to rack bar connection as per instructions in TIB dated April 22, 1998 titled "Loose Rivet in Rack Control Assembly".

3. Remove rack control assembly and fuel injectors from cylinder head.

4. Remove the cylinder head, aftercooler, turbo, and exhaust manifold per the Service Manual. The aftercooler does not have to be disconnected from the intake manifold for removal.

5. Remove the 1136180 Intake Valves from the cylinder head.

6. Remove the 1014541 Exhaust Valves from the cylinder head.

7. Dress each exhaust valve seat. Maintain recession of the valve head 1.51 - 2.22 mm (0.059 - 0.087 in) below the fire deck surface of the cylinder head.

8. Dress each intake valve seat. Maintain recession of the valve head 1.13 - 2.05 mm (0.044 - 0.081 in) below the fire deck surface of the cylinder head.

9. Ream fuel injector sleeves to get a good seat for the injector cone (replace sleeves if needed).

NOTE: It is not necessary to completely remove the sealing ring indentation in the sleeve if it is uniform all around. Refer to March 1999 Engine News on how to use the new 1709227 Reamer Shims. 10. Install (6) new 1577125 Intake Valves in cylinder head.

11. Install (6) new 1577126 Exhaust Valves in cylinder head.

12. Install new valve stem seals.

13. Install the reworked cylinder head on the engine. (Lubricate heads bolts with 6V4876 Molly Lubricant)

14. Inspect injector cone seating surface for damage.

15. Remove and discard tip O-ring from injector. Replace top O-ring with new and install injector using a 1731530 Injector Seating Tool.

16. Ensure that rack linkage is unrestricted and all injectors are synchronized properly as per instructions outlined in TIB dated April 28, 1999 titled "Low Idle Instability".

17. If conditions permit, run 1/2-hour loaded engine test in boat. After jacket water temperature is up to 180F, run 20 minutes @ 2500 Rpm and 10 minutes @ full throttle. Engines should run 2700-2900 Rpm at full throttle without significant combustion gas in fuel return line.