Usage:
May 8, 2000
(Revised July 2001)
U-138
A-110
AU-82
S-64
O-124
| Priority |
THE ENGINE CYLINDER BLOCK MAIN CAPS NEED TO BE INSPECTED ON CERTAIN 5130B AND 5230 EXCAVATORS; 994D, 992G AND 854G WHEEL LOADERS; 793C, 789C, 785C HAA, 785C, 785B, 777D HAA, 777D AND 776D OFF HIGHWAY TRUCKS; D11R TRACK TYPE TRACTORS; NEW AND REMAN 3500 ENGINES |
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| 1201 |
PI30025
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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.
NOTE: For the proper inspection and rework procedure of 3500 Commercial Engines, refer to PI30053
NOTE: This Revised Service Letter replaces the May 8, 2000 (Revised June 2001) Service Letter. Changes have been made to the Affected Product.
COMPLETION DATE |
TERMINATION DATE |
| November 30, 2000 | November 30, 2001 |
PROBLEM
A process was omitted during the manufacturing of certain 3500 Engine cylinder block main caps. Because of the omitted process, there is a chance the main cap may crack and cause the crank to operate unsupported. The unsupported operation of the crank may cause the crankshaft to break and may cause an engine failure.AFFECTED PRODUCT
Model Identification Number793C
ATY183
4GZ94-135, 138-202, 204-208, 212-250, 256-260
4AR376-379, 382-383, 385-424
789C 2BW90-133, 135-149
785C HAA 5AZ90-114, 264-266, 268, 269
- 785C APX160-164
- 1HW87?131
777D HAA 2YW99-105
- 777D AGC77-160, 165, 167-170, 173-176
- 3PR874-1126
- 776D 5ER94-127
- D11R AAF132
- 7PZ286-292, 294-299
- 9TR304-473
- 9XR160-189
- 5130B 4CS155-160, 162, 164-165
5230
7LL99-100
994D 3TZ251-265
992G
ADZ127-130, 132-133
7HR254-256, 258-335, 338-386
854G 1JW237-244
ANY MACHINE SERIAL NUMBERS WITH THE FOLLOWING NEW OR REMAN ENGINES INSTALLED.
3508 MUI
99W03529-3540
4ZL539, 543-545, 551, 554, 556, 558, 561, 573, 575, 576,
586-588, 590, 593-596, 598-600, 604, 606, 607, 613, 618,
626, 628, 629, 633, 635, 636, 638, 639, 643, 645, 647, 649,
655, 657, 659, 661
3508 EUI
7YG02171-2178, 2180-2181, 2184-2190
5TL298-300, 305, 306, 315, 316, 321, 330, 334, 336, 338,
346, 349, 351, 362, 365,369, 370-376, 379, 380, 386, 390
3508 "B"
2GR1448-1945, 1947-1960, 1962-1965, 1967-2040,
2042-2142, 2144?2189, 2191-2195, 2197-2222,
2224?2226, 2228-2230, 2232-2240, 2242-2255,
2259-2261, 2263-2265, 2267, 2268, 2270, 2271,
2273-2275, 2277-2282, 2284, 2286, 2287, 2290-2292,
2294, 2298, 2299, 2303, 2306, 2307, 2309, 2313, 2321,
2326, 2332, 2337
3512 MUI
96Z932-934
5EL201-203, 211, 213
3512 EUI
4WJ1228-1257
6FL208, 220, 225, 230, 236, 238, 259, 261, 269-270,
276-278, 284,289-290, 292, 294, 299-300, 302, 304, 399,
401, 403
3512 "B" 8BR544-598, 601, 604-605, 607, 614-617
- 3516 MUI 54Z1192-1197
- 6CL316, 319, 321, 326, 332, 336, 337, 340-343, 346-350, 352, 356
7CL580-581, 591-596, 600, 609-611, 618-620, 625,
631, 637, 638, 643-645, 649, 653, 654, 656, 658,
661, 665, 666, 670, 671, 673, 674, 680, 681-684,
687, 689-700, 702, 708, 710-713, 715, 717, 718,
720, 729, 735, 738-740, 746, 753, 754, 756, 758-762,
764, 765, 767, 772, 774, 776-780, 782, 785, 788-792,
794-797, 799, 800, 803, 806, 807, 811, 815, 818, 820,
822, 823, 826, 829, 831, 832, 834, 835, 842, 843
3516"B"
7TR573-790, 793-836, 838-859, 861-865, 867-871, 875,
881-887, 889-904, 906, 909-911, 913-926, 930-941,
943-945, 947-951, 954, 955, 959, 960, 962, 964, 965,
970-974, 978-994
7DS154-158, 162-166, 169, 170, 172-177, 180, 181
MACHINE MODELS LISTED ABOVE WITH ANY OF THE FOLLOWING CYLINDER BLOCKS INSTALLED.
CYLINDER BLOCKS
3508 115-3503 BLOCK AS. CYL. (SEQUENCE NO.
62A-001 - 94A-999)
3512 115-5154 BLOCK AS. CYL (SEQUENCE NO.
62B-001 ? 94B-999)
3516 115-5160 BLOCK AS. CYL. (SEQUENCE NO.
62C-001 - 93C-999)
Every effort should be made to inspect and peen all affected engines immediately. However, if any of the above listed engines have reached overhaul or do not have the 'D05' or 'R05' stamp during overhaul, these engines should be inspected for cracks and needle peened during the overhaul.
PARTS NEEDED
8 CYL. ONLY1 - 7E-2631 GASKET-OIL
2 - 132-6260 SEAL-INTEGRAL
12 CYL. ONLY
1 - 7E-2630 GASKET-OIL
1 - 142-4159 SEAL-INTEGRAL
1 - 7M-7260 GASKET MAKER
2 - 3P-0657 SEAL-O-RING
1 - 6V-5101 SEAL-O-RING
2 - 109-2332 SEAL-O-RING
ACTION REQUIRED
See the attached Rework Procedure.OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification.SERVICE CLAIM ALLOWANCES
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| Costs associated with Needle Peening tool. | |||
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| Costs associated with Magnetic Particle Inspection Tooling or outside charges provided the dealer is not to qualified to do the inspection. | |||
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| 793C |
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| 789C |
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| 785C HAA |
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| 785B, 785C |
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| 777D HAA |
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| 777D/776D |
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| 994D |
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| 992G |
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| 854G |
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| 5230 |
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| 5130B |
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| D11R |
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| 3508 |
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| 3512 |
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| 3516 |
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PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach. (1-Owner Notification)
(1-Rework Procedure)
(1-Appendix)
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - THE ENGINE CYLINDER BLOCK MAIN CAPS NEED TO BE INSPECTED
MODELS INVOLVED - CERTAIN 5130B AND 5230 EXCAVATORS; 994D, 992G AND 854G WHEEL LOADERS; 789C, 793C, 785C HAA, 777D AND 776D OFF HIGHWAY TRUCKS; D11R TRACK TYPE TRACTORS; NEW AND REMAN 3500 ENGINES
Dear Caterpillar Product Owner:
A process was omitted during the manufacturing of certain 3500 Engine cylinder block main caps. Because of the omitted process, there is a chance the main cap may crack and cause the crank to operate unsupported. The unsupported operation of the crank may cause the crankshaft to break and may cause an engine failure. The main caps need to be inspected in the products listed below. You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated May 8, 2000 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to May 8, 2000 Service Letter
Rework Procedure
Required Tools:
- AC magnetic particle inspection yoke1.
- Longwave UV lamp (3650 angstrom wavelength; minimum 1000 micro w/cm2 intensity)1
- 195-4730 Can of Commercial, fluorescent magnetic particles in suspension, preferably oil1
- 190-0783 peen tool or a needle peen air tool with between 12 and 20 rounded tip steel needles 3 mm (3/16 inch) in diameter.
- A 193-0396 Peen Tool can be used for D11 engines due to the limited access created by the frame cross-member. The 193-0396 Peen tool is a compact peen tool used for peening commercial engines.
- Rubber to protect machined surfaces during peening (included with the 190-0783 peening tool).
This rework program shall be carried out with the bearing caps installed in the engine and the engine in the machine chassis.
The oil pan will have to be removed and covered to prevent excess debris from getting in the oil system.
This repair is best made during an oil change since the oil will have to be drained to remove the oil pan.
- Magnetic Particle Inspection ? Engines that have been in service must have all main caps inspected for cracks using magnetic particle inspection. Magnetic particle inspection is not required for engines that have not yet been placed into service.
The magnetic particle inspection yoke must
use alternating current (AC) to prevent excess residual magnetism.
When performing the inspection inside the engine, wet florescent magnetic particles should be used since black particles will be difficult to see. Dry particle testing is not recommended due to low sensitivity.
- Use a cloth to thoroughly clean any oil from the bottom surface of the main cap.
- Inspect the entire length of the 2 fillets on the bottom of the main cap for cracks. Refer to Illustration 1 for the location of possible crack origination. Refer to Illustrations 2 and 3 for yoke placement.
- Energize the yoke on the cap to induce the magnetic field. Apply the magnetic particle solution between the feet of the yoke while the yoke is energized.
- Discontinue solution prior to stopping alternating current.
- Both front and rear of each fillet must be magnetized since alternating current does not extend through the width of the cap.
- Using appropriate ultraviolet light source, illuminate the radius and inspect for crack indications. If present, cracks will appear at the root of the fillet radius as shown in Illustration 4. A hood or other means of blocking out ambient light may be needed to detect very small cracks.
- No cracks in the main cap are permitted. Cracks are not repairable. Do not perform the remainder of this procedure if any cracks are found.
Engine repair options include:
- Replace the cracked cap and line bore the block.
- Replacement of the block.
- Installation of a Reman or dealer swing engine.
- Demagnetize the cap after inspection by placing and energizing the yoke at previous locations and drawing yoke away while still energized. Draw the yoke away from any magnetizable components for a distance of at least 12-15 inches before discontinuing the current. This will avoid inadvertently re-magnetizing any engine components. However, it is not necessary to perform the demag operation slowly. The inspector can draw the yoke away rapidly and still be successful in demagnetizing.
Illustration 1
Illustration 2. Location of AC yoke for magnetic particle inspection
Illustration 3. Location of AC yoke avoiding counterweight for magnetic particle inspection.
Illustration 4. Small crack at root of main cap fillet radius seen using magnetic particle inspection method
Illustration 5 - Main cap bevel (A), cast surface (B), root of fillet radius (C), and duct tape (D) securing rubber peening mask.
Illustration 6 ? Rectangle shows area to be peened. Protect machined surfaces when reworking outside engine
- Remove the engine oil pan as instructed by the Disassembly and Assembly Manual for the particular machine being reworked.
- Needle peen the entire rough cast area on the bottom of the cap inside the rectangle shown in Illustration 6. The main areas of concern are the roots of the fillet radii along the bottom of the cap shown in Illustration 5, item C. Peen over the edge of the flat surface onto the bevel shown in Illustration 5. Peening should stop on the bevel. It is not necessary and not recommended to peen over the edge of the bevel onto the machined surface on the side of the main cap.
- The machined bolt seat face should be protected while peening. When reworking outside the engine, use a 6 mm (1/4 inch) thick piece of rubber secured by duct tape as shown in Illustration 5. When reworking in the engine, use a 6mm (1/4 inch) thick piece of rubber that stretches over the bolt heads as shown in Illustration 7. Other similar methods of protecting the machined surfaces may also be used. One such method is four layers of duct tape over machined surfaces next to peening locations.
- Peen with a 190-0783 or similar peening tool
- Supply air pressure between 552 and 758 kPa (80 and 110 psi) to the peening tool.
- Peen with between 12 and 20 rounded tip steel needles 3 mm (3/16 inch) in diameter. Do not use flat tipped or square shaped needles. The edges of flat tipped needles may be rounded off using a grinder if necessary.
- Peen the area shown in Illustration 6 for a duration of approximately 3 minutes. Spend most of the time along the radii of the cap where the bolt faces transition to the bottom of the cap where the part number is located as indicated by the circled section in Figure 1. There is little risk of damage by peening too long. However, no additional benefit will be gained by additional peening. Peening the area for less than 3 minutes may not give the necessary material enhancement.
- The peening angle should be approximately perpendicular to the cap. See Illustrations 8, 9, and 10
- It may be necessary to rotate the engine so that crankshaft counterweights do not interfere with the peening process.
Illustration 7. Protecting machined surfaces when reworking inside engine.
Illustration 8. Peen starting at the base of
one fillet.
Illustration 9. Continue peening across the entire as cast surface.
Illustration 10. Continue peening all the way into the base of the opposite fillet.
Note: The entire process should be at least three minutes. Going back over already peened surfaces is acceptable.
- Clean the main caps by wiping with a clean, oiled rag or some other method to remove any loose debris.
- Wipe down the connecting rods, pistons, and bottom end of the liners with a clean, oiled rag to remove any loose debris.
| Item | Description | Manufacturer | Mfg Model No. | Mfg Part No. |
| Magnetizing Yoke | AC - 115V, 50/60 Hz |
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Y-6 |
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| Magnetizing Yoke | AC ? 220V, 50/60 Hz |
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Y-6 |
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| Magnetizing Yoke | AC ? 220V, 50 Hz |
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JWM 220 |
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| UV Light & Transformer | 115V, 60 Hz (also available 220V, 50Hz); Carrying handle for portability |
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ZB-100P |
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| UV Light & Transformer | 115V, 60 Hz (also available 220V, 50Hz), No carrying handle |
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ZB-100 |
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| UV Light & Transformer | Available for any power source? |
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MB-100 or SB-100P or C-100 or SSC-100 |
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| UV Light & Transformer | 220V, 50H |
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| Replacement bulb for UV lamp | 100W |
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| Replacement bulb for UV lamp | 100W, Spot bulb |
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100S |
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| Replacement bulb for UV lamp | 100 W |
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| Fluorescent particles in oil | Aerosol, case of 12? Cans |
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14AM |
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| Fluorescent particles in oil | Aerosol, 400ml |
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Fluoflux |
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Magnaflux: Product as well as U.S. & International Sales Rep. Info can be obtained at: http://www.magnaflux.com/
Offices: 3624 W. Lake Ave / Glenwood, IL 60025, USA
/ Phone: 847-657-5300 / Fax: 847-657-5388
Faraday Rd, S.Dorcan Industrial Estate / Swindon, Wiltshire,
SN3 5HE, England / Phone: 44-793-524566
5, SP Road, Begumpet / Hyderabad 500 016, India /
Phone: 91-40-814892
Rua Piratininga / 235-Jardim Ruyce / 09990-020-Diadema-SP
/ Brazil / Phone: 011-55-713-2044
Tiede: Web site: http://www.tiede.de/
Tiede GmbH + Co / Rissprüfanlagen / Bahnhofstraße
94 ? 98 /D-73457 Essingen / Germany / 49(0)7365 81-0
CANDET / 124 Skyway Avenue / Rexdale, Ontario M9W 4Y9
/ Canada / phone: 001 - 4162138000
Av. Independencia #1850, 1 erPiso / Jardines dela Concepcion
/20120 Aguascalientes / Mexico/0052? 49123700
Av. Belgrano 369 / AR - 1092 Buenos Aires / Argentina
/ Telephone: 0054 - 1143314503
Unit 5, 8th Floor, Kodak House II / 39 Healthy Street
East / North Point / Hongkong /Ph: 00852 - 28563280
N.S.W. Office/ 551 Pittwater Rd. / 2100 Brookvale / Australia
/ Telephone: 0061 - 9285700
Spectronics/Spectroline: 956 Brush Hollow Rd / Westbury NY 11590 / USA / Phone: 1-800-274-8888