Product Support Program For Repairing Engines That Fail Due To Cracked Main Bearing Caps On Certain 3508, 3512 And 3516 Engines Used In Off-Highway Trucks, Track-Type Tractors, Hydraulic Excavators And Wheel Loaders Or Generator Set, Industrial, Mari Caterpillar

Product Support Program For Repairing Engines That Fail Due To Cracked Main Bearing Caps On Certain 3508, 3512 And 3516 Engines Used In Off-Highway Trucks, Track-Type Tractors, Hydraulic Excavators And Wheel Loaders Or Generator Set, Industrial, Mari

Usage:

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Caterpillar: Confidential Yellow

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 'PS50078' 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.

Termination Date

June 30, 2002

Problem

Engines may need to be repaired due to cracked main bearing caps on certain 3508, 3512 and 3516 Engines used in off-highway trucks, track type tractors, hydraulic excavators and wheel loaders or generator set, industrial, marine, locomotive, marine auxiliary and vehicular applications. A process was omitted during the manufacturing of the cylinder block main caps on certain 3500 Engines. Because of the omitted process, the main cap may crack. This crack may be detected during a regular maintenance interval or in the worst case, the crack may not be detected until the engine fails.

Affected Product

Section 1 - Machine Engines

Group 1

776B (6JC1-UP)

777B (4YC1-UP)

776C (2TK1-UP)

777C (4XJ1-UP)

776D (5ER1-UP)

777D (3PR1-UP)

776D (AFS1-UP)

777D (AGC1-UP)

D11N (74Z1-UP, 4HK1-UP)

D11R (9TR1-UP, 9XR1-UP, 8ZR1-UP)

D11R (AAF1-UP, 7PZ1-UP)

992G (7HR1-UP, ADZ1-UP)

854G (1JW1-UP)

5130 (7TJ1-UP, 5ZL1-UP)

5130B (4CS1-UP)

Group 2

785C (1HW1-UP, APX1-UP)

785B (6HK1-UP)

777D HAA (2YW1-UP)

Group 3

789 (9ZC1-UP)

789B (7EK1-UP)

789C (2BW1-UP)

793 (3SJ1-UP)

793B (1HL1-UP)

793C (4AR1-UP4GZ1-UP, ATY1-UP)

785C HAA (5AZ1-UP)

5230 (7LL1-UP)

994 (9YF1-UP)

994D (3TZ1-UP)

Section 2 - Commercial Engines

Group 1

3508 (23Z1-UP, 5PW1-UP, 70Z1-UP, 3LS1-UP, 5XM1-UP, 97Y1-UP)

3508B (2HW1-UP, 4GM1-UP, 6PN1-UP, 5KW1-UP, 68Z1-UP, 95Y1-UP, 69Z1-UP, 96Y1-UP, 3HM1-UP, 9WN1-UP, 3PS1-UP, 5PS1-UP, 1TW1-UP, 2BM1-UP, 7SM1-UP, 3DM1-UP, 3DW1-UP)

Group 2

3512 (2WK1-UP, 1LM1-UP, 49Y1-UP, 65Z1-UP, 24Z1-UP, 67Z1-UP, 6WW1-UP, 3MS1-UP, 6PM1-UP, 50Y1-UP, 66Z1-UP, 3RS1-UP, 51Y1-UP, BAG1-UP, 3WS1-UP)

3512B (8EM1-UP, 2GW1-UP, 4TN1-UP, 7HM1-UP, 2EZ1-UP, 4AW1-UP, 6WN1-UP, 8RM1-UP, 6GW1-UP, 5AW1-UP, 3ZW1-UP, 8DF1-UP)

3512B M/ (1PW1-UP)

Group 3

3516 (3XS1-UP, 25Z1-UP, 5SJ1-UP, 73Z1-UP, 8TW1-UP, 27Z1-UP, 71Z1-UP, 29Z1-UP, 72Z1-UP, 3SS1-UP)

3516B (3CW1-UP, 8CN1-UP, 8KN1-UP, 4BW1-UP, 3NS1-UP, 7KM1-UP, 1NW1-UP, 6HN1-UP, 7RN1-UP, 8NW1-UP, 2JW1-UP, 9WF1-UP, 2FW1-UP, 9AN1-UP)

DV098 (3JS1-UP)

DV099 (2TS1-UP)

E110B (9HF1-UP)

Failure Identification:

The failure mode of a broken main cap can occur at any SMU. To identify a main bearing cap crack that qualifies for this program, the cap must have a crack similar to the cap in Illustration 1 below. The crack MUST initiate from the either fillet radius of the cap. The cap may only be cracked or may be broken in two pieces.

NOTE: Main caps with cracks in any other position DO NOT qualify for the program.

Illustration 1

Parts Needed

Group 1

1 - 1524994 Crankshaft Assembly (for 3508 only)

-Or-

1 - 1527625 Crankshaft Assembly (for 3508B)

1 - 1153503 Block Group-Cylinder (for 3508 and 3508B)

Group 2

1 - 1286786 Crankshaft Assembly (for 3512 and 3512B)

1 - 1155154 Block Group-Cylinder (for 3512 and 3512B)

Group 3

1 - 1286788 Crankshaft Assembly (for 3516 and 3516B)

1 - 1155160 Block Group-Cylinder (for 3516 and 3516B)

Action Required

See that attached Rework Procedure.

Service Claim Allowances

Option I: The dealer repairs failed engine.

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

Section 1 - Guidelines for Reusable Parts and Special Instructions:

The following is a list of Guidelines for Reusable Parts and Special Instructions for 3500 Cylinder Blocks and 3500 Crankshafts. These publications are listed as a reference in the event that they are needed during the repairs.

3500 Cylinder Blocks

Guidelines for Reusable Parts

SEBF8076 'Specifications to Salvage Cylinder Block Contact Surfaces'

SEBF8157 'Specification for Cylinder Blocks 3500 Family of Engines'

SEBF8164 'Specifications for Liner Measurement and Salvage 3500 Family of Engines'

SEBF8219 'Salvage of Cylinder Block Liner Bores for 3500 Family of Engines'

SEBF8255 'Procedure to Install Top Deck Liner Seat Inserts in Cylinder Blocks of 3500 Engines'

SEBF8263 'Procedure to Repair Top Deck Pitting on Cylinder Blocks of 3500 Engines'

SEBF8291 'Top Deck Threaded Hole Repair in 3400 and 3500 Series Engines'

SEBF8387 'Main Bearing Bolt Repair in 3400 and 3500 Series Engines'

Special Instructions

SEHS8869 'Cylinder Block Salvage Procedure Using Belzona Ceramic R Metal'

SMHS8418 'Cylinder Block Cleaning Procedure'

SEHS8776 'Installation of Service Replacement Cylinder Block Group'

SEHS9826 'Ordering Series B Replacement Cylinder Blocks for 3500 Series Engines'

SMHS7606 'Use of 1P4000 Line Boring Tool Group'

3500 Crankshafts

Guidelines for Reusable Parts

SEBF8039 'Inspection of Crankshafts for Cracks'

SEBF8043 'Visual Inspection of Crankshafts'

SEBF8041 'Crankshaft Measurement'

Section 2 - Possible Failure Modes

There are two failure modes for broken main bearing caps. The first mode is an engine failure resulting from an undetected broken main bearing cap. This failure is destructive and usually results in a broken block and crankshaft. The engine is in an inoperable condition and must be repaired.

The second failure mode is cracked or broken main cap or caps. This type of failure is discovered during an inspection of the main cap using a magnetic particle inspection technique or visually noticing a broken main bearing cap. If a cracked or broken main cap is found, the engine should NOT be operated due to the risk of causing an engine failure, further damaging the engine.

For both failure modes, the engine will need to be repaired. Repair options will vary based on the circumstances of each failure. Section 3 outlines the repair options for each failure mode.

Section 3 - Engine Repair Options

All engines with cracked or broken main bearing caps will require the engine block to be replaced or line bored. This will require that the engine be removed and disassembled.

Once the engine has been disassembled, the block and crankshaft can be inspected and the determination made as to which repair option needs to be taken. The table below outlines the repair options for the cylinder block and crankshaft based on the extent of the failure.

Block and Crank Repair Options Matrix:

NOTE: A cracked cap is defined as a cap that has cracked but is not broken in two separate pieces.

Block Repair Options:

Block Option 1 - Repair for a Cracked Cap(s) Only:

With a cracked cap only, the chance of contingent cylinder block damage is relatively low.However, the block still needs to be inspected for damage and reusability verified.

1. Inspect all other main bearing caps for cracks per Procedure 1. Cracked caps must be replaced.

2. Inspect the 'Z-Lock' width per Procedure 2.

3. Inspect and check all main bearing bores per SEBF 8157.

4. Visually inspect entire block for damage. Provided above inspections determine the cylinder block is reusable, the cracked main bearing caps need to be replaced and the cylinder block must be line bored oversize.

5. Replace cap and line bore to size.

NOTE: Line bored cylinder blocks must meet the specifications called out in SEBF8157.

Dealers who are do not have the equipment or the capability to correctly line bore the block are not expected to line bore in order to complete the repair. In this case a new cylinder block should be installed. Dealers who have the equipment and experience to properly line bore should do so if the cylinder block meets the above guidelines.

Block Option 2 - Repair for Broken Cap(s)

Blocks with broken caps have a high probability that contingent damage has occurred. These blocks need to be carefully inspected for other damage.

1. Inspect all other main bearing caps for cracks per Procedure 1. Cracked caps must be replaced.

2. Inspect the 'Z-Lock' width per procedure 2.

3. Inspect and check all main bearing bores per SEBF 8157.

4. Inspect block for cracks per procedure 3. Provided above inspections determine the cylinder block is reusable, the cracked main bearing caps need to be replaced and the cylinder block must be line bored oversize.

5. Replace cap and line bore to size.

NOTE: Line bored cylinder blocks must meet the specifications called out in SEBF8157.

Crankshaft Repair Options

Crankshaft Option 1 - Cracked Main Cap(s), No Spun Bearings.

For crankshafts that have operated with a cracked cap(s) only, the crankshaft can be cleaned, inspected and reused per SEBF 8043.

Crankshaft Option 2 - Broken Main Cap(s), No Spun Bearings.

For crankshafts that have been operated with a broken main cap(s) and have not spun a main bearing, there is a chance that crankshaft could be cracked due to unsupported operation.Crankshafts that fall into this category need to be inspected as follows.

1. Visually inspected per SEBF8043.

2. Inspected for cracks in the main journal fillets per SEBF 8039. Crankshafts that are found to have cracking in the main journal fillets are not to be reused.

Crankshaft Option 3 - Broken Main Cap(s), Spun Main Bearings

Crankshafts that have been operated with a broken main cap(s) and have spun a main bearing need to be replaced with a new crankshaft.

Section 4 - Warranty Claim Information

When filing the warranty claim following this failure, the following information must appear in the claims story.

1) Location of the Cracked or Broken Main Cap(s) (Ex. 7 main)

2) Main Cap Heat Code - See Illustration 1

3) Cylinder Block Sequence Number - See Illustration 2

4) Engine Serial Number

Illustration 1 - Location of Main Cap Heat Code

Illustration 2 - Location of Block Sequence Number

Procedure 1 - Inspecting Main Bearing Caps for Cracks.

It is best to inspect main bearing caps for cracks with the bearing caps installed in the block. The loads placed on the bearing caps while installed in the block will make cracks easier to detect.

Required Tools:

* AC magnetic particle inspection yoke

NOTE: The magnetic particle inspection yoke must use alternating current AC) to prevent excess residual magnetism. DO NOT use an AC magnetic inspection tool that uses electrical current through the main bearing cap. ONLY use a tool that places a magnetic field through the cap.

* Longwave UV lamp (3650 angstrom wavelength; minimum 1000 micro watt/c intensity)

* Commercial, fluorescent magnetic particles in suspension, preferably oil

See Appendix A, at the end of this procedure, for part numbers and tool suppliers.

Procedure

1. Use a cloth to thoroughly clean any oil from the bottom surface of the main cap.

2. Inspect the entire length of the 2 fillets on the bottom of the main cap for cracks. Refer to Illustrations 3 and 4 for yoke placement. It is acceptable to place the yoke on the main bolts.

3. 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.

4. Discontinue solution prior to de-energizing the yoke.

NOTE: Both fillets must be magnetized since alternating current does not extend through the width of the cap.

5. 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 5. A hood or other means of blocking out ambient light may be needed to detect very small cracks.

6. 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 component that could possibly be magnetized 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 demagnetized operation slowly. The inspector can draw the yoke away rapidly and still be successful in demagnetizing.

Illustration 3 - Location of AC yoke for magnetic particle inspection

Illustration 4 - Location of AC yoke avoiding counterweight for magnetic particle inspection.

Illustration 5 - Small crack at root of main cap fillet radius seen using magnetic particle inspection method

Procedure 2 - Measuring the 'Z-lock' Width

Any main bearing cap seat, which has experienced operation with a cracked or broken main bearing cap needs to have the 'Z-lock' width, checked for the proper size.

Illustrations 6 and 7 show the proper specification for measuring the 'Z-lock' width. The width should be measured in three different places (forming a triangle) across the thickness of the main cap seat. See Illustrations 6 and 7 for suggested locations to measure the 'Z-lock' width.

The 'Z-lock' width specification is 339.985 mm ± .015 mm. Blocks that measure outside of this specification should be scraped.

Illustration 6 - 'Z-lock' Width

Illustration 7 - Cylinder Block Bottom View

Procedure 3 - Inspection for Block Cracking

When a main bearing cap breaks, often times contingent block damage is done. In the majority of the failures the block will crack in the saddles of the block. Some cracks are very small and others can be easily seen.

Using the tooling and methods described in procedure 1, the block needs to be inspected in the areas detailed in Illustration 8 and 9.

If any cracking is found in these areas, the cylinder block must be scrapped. Cracking in this area is not repairable.

Illustration 8 - Possible Block Cracking