PROBLEM

AFFECTED PRODUCT

3508. 1153503 Cylinder Block As. (Sequence No. 65A001 To 94A999)

3516 1155160 Cylinder Block As. (Sequence No. 65C001 To 93C999)

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

ACTION REQUIRED

MARINE CERTIFIED ENGINES

If the engine is a marine propulsion or marine auxiliary that has been delivered with a marine society certification (i.e. Lloyd?s Register, etc.), the customer must notify the local office of the society involved PRIOR to carrying out this rework. See "Service Claim Allowances" for costs associated with the marine society inspection.

OWNER NOTIFICATION

SERVICE CLAIM ALLOWANCES

PARTS DISPOSITION

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
 
 

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

PRIORITY - Main Bearing Caps May Crack And Need To Be Inspected

MODELS INVOLVED - 3506, 3512 and 3516 Engines

Dear Caterpillar Product Owner:

Main bearing caps may crack and need to be inspected on certain 3508, 3512 and 3516 Engines. A process was omitted during the manufacturing of certain main caps use in 3500 engine cylinder block. Because of the omitted process, there is a chance that the main cap may crack and cause the crank to operate unsupported. The unsupported operation of the crankshaft may cause the crankshaft to break and may cause an engine failure. Main bearing caps need to be inspected and reworked on the products listed below.

If the engine is a marine propulsion or marine auxiliary that has been delivered with a marine society certification (i.e. Lloyd?s Register, etc.), the local office of the society involved must be notified PRIOR to carrying out this rework.

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 July 17, 2000 when scheduling this service. You will not be charged for the service performed.

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)

Required Tools:

• 1933289 (115V) or 1933290 (230V) - AC magnetic particle inspection kit.

• 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

• 193-0396 Peen Tool for reworking caps inside the engine.

• Telescoping Mirror
• 9S9082 Engine Turning Tool

Preface:

To achieve the maximum benefit of needle peening, caps must be inspected and reworked while inside the engine. It is NOT recommended that caps be removed from the engine in order to perform this procedure.

If access is available and it appears to be easier to raise the engine up and remove the oil pan than to rework through the side covers, the procedure, tools and parts required from the machine engine PIP (PI30025) should be used.

This rework is best preformed with two mechanics. There are times in the rework that two mechanics are required to perform the procedure properly.

Certain installations may require that backup power be installed during the time in which the engine is taken offline for this rework. The charges associated with rental and hook up of backup power can be charged, at cost (not sell rate) to this program with prior approval of the dealers' Caterpillar Rep. If not preapproved by the Caterpillar Rep. the claim will be rejected. Caterpillar Rep. is responsible to notify warranty of his preapproval and amount approved.
 

The following information must be provided to the Caterpillar Rep. to justify approval of backup power rental:

- Description of why backup power rental is required.

- Number of days rental required.

- Number of gen sets and their S/N's to be reworked while backup rental power on site.

- If more than 12 hours required to install/remove backup generator a detailed description of why additional install/remove labor hours are required.

- Total rental expense at cost (not sell rate).

If Caterpillar Rep. wants factory assistance to help determine approval the Rep. may contact Kevin Storms (ph. 765-448-5911, stormkp@cat.com) or Jim Reynolds (ph. 765-448-5113, reynoje@cat.com).
 

The 'Install and Remove Backup Generator' labor claim allowance is '12 hours maximum at cost (not sell rate)'. Preapproval by dealers Caterpillar Rep. is required, as outlined above, to claim more than 12 hours.
 

If actual claim dollars are greater than preapproved the excess will be rejected.
 

3rd Party Enclosures (non Cat enclosure):

Certain installations with 3rd party enclosures may require some disassembly of enclosure for access to the engine to perform rework. A maximum of 40 hours disassembly/reassembly labor at cost (not sell rate) may be charged to this program with prior approval of the dealers Caterpillar Rep. If not preapproved by Caterpillar Rep. the claim will be rejected. Caterpillar Rep. is responsible to notify warranty of his preapproval and amount approved.
 

The following information must be provided to the Caterpillar Rep. to justify his approval:

- Description of why 3rd party enclosure disassemble is required for access to engine.

- Disassembly/reassembly labor hours required.

- Total labor expense at cost (not Sell Rate)
 

If actual claim dollars are greater than preapproved the excess will be rejected.

MARINE CERTIFIED ENGINES

If the engine is a marine propulsion or marine auxiliary that has been delivered with a marine society certification (i.e. Lloyd?s Register, etc.), the customer must notify the local office of the society involved PRIOR to carrying out this rework. Do not begin this rework unless the customer has contacted the appropriate marine society for approval.

Engine Preparation:

Before beginning the rework procedure the engine oil must be drained from the oil pan.

All-peripheral iron such as air starters, oil pumps, water pumps and, oil coolers should be removed to allow access to both sides of the engine. All crankshaft inspection covers should be removed, as access to both sides of the main caps will be required.

Magnetic Particle Inspection:

Engines that have less than 20 hours of service do not have to be inspected for cracks. All engines with 20 hours or more must have ALL main caps inspected for cracks using magnetic particle inspection.
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.
The person performing the inspection should read and understand the operating manual for proper use of magnetic inspection equipment.

1. Plug in black light to allow it to warm up and reach maximum intensity.
2. Position crankshaft such that the counterweights are on the top and connecting rods are on the bottom of the window through which the main cap is to be inspected.
3. Use a cloth to thoroughly clean any oil from the bottom surface of the main cap.
4. The entire length of both fillets on the bottom of the each main cap needs to be inspected for cracks. Refer to Illustration 1 for the location of possible crack origination. Refer to Illustrations 2 and 3 for yoke placement. (Illustrations were taken from the bottom of the engine with the oil pan removed to show proper placement of the yoke. Oil pan removal is not required.)


NOTE: Thoroughly shake the cans of fluorescent particle solution prior to spraying to ensure proper mixing.

5. 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.
6. Discontinue solution application prior to stopping alternating current to ensure particles are not washed off any indications.
7. Both the left and right fillet must be magnetized separately since alternating current does not extend through the width of the cap.
8. Using appropriate ultraviolet light source, illuminate the radius and inspect with mirror for crack indications. If present, cracks will appear at the root of the fillet radius as shown in Illustration 4.
9. 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.

1. Replace the cracked cap and line bore the block.
2. Replacement of the block.
3. Installation of a customer or dealer swing engine.

1. 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 as far as practical from the cap before discontinuing the current. This will avoid inadvertently remagnetizing any engine components.

 
 

 
 

Illustration 1 ? Location of Crack Origination

Illustration 2 - Location of AC yoke

Illustration 3 - Location of AC yoke avoiding the counterweight

Illustration 4 - Small crack at root of main cap fillet radius

Main Cap Terminology:

Through the next sections of this program, several different features of the main cap will be referred to. Illustration #5 points out several features of the main cp. Those features are as follows:

1. - Main cap bevel
2. ? 'As cast' surface
3. - Fillet radius.

Needle Peen Tool Design:
 

The 193-0396 Needle Peen Tool was specially designed for main cap peening through the crankshaft inspection windows. This tool was developed to be used in all shallow and deep sump oil pans. A 193-0396 tool does not include a required handle / extension arm. The dealer should make this extension arm before beginning the peening procedure.
 

Appendix B gives a complete print of the peening tool with the extension handle. The lengths of pipe mentioned in Appendix B are only recommendations. The actual lengths of the pipes may be adjusted to fit any engine due to the unique conditions of each installation.
 

It is not recommended that the peening head be used without an extension, handle, or extensions made of flexible hose. The vibration of the peening head makes it difficult to hold and control the peening tool without a handle. Peening multiple caps or engines will be difficult without the handle described in Appendix B.
 

The compression joint nearest the peening head will allow easy adjustment of the peening head. Adjustment of the peening head is needed for peening the fillet radius at the appropriate angle. The other compression joint allows the entire head to be located on the other side of the handle, allowing for peening caps from both sides of the access window or engine.
 

Needle Peening Preface:
 

Two mechanics are needed to operate the needle peen tool, one on each side of the engine. Although one mechanic can use the peen tool, it is not recommended for two reasons. First, controlling the peen tool to ensure coverage in all areas is difficult. Second, the peen tool may seize during operation due to misalignment of the piston as it impacts the cap.
 

The first mechanic is the Holder. The Holder operates the air on/off valve and uses the extension handle to help hold the peening head on the main cap. The Holder should only apply enough upward force required to keep the peening head from bouncing on and off the bottom surface of the cap.
 

The second mechanic is the Controller. The Controller reaches in the access window on the opposite side of the engine from the Holder. The Controller reaches through the inspection window and places the peening head in the palm of one hand. The other hand is reaching through the adjacent inspection window and uses the small handle on the base of the peening head to guide the peen tool along the bottom of the cap and in the fillet radii.

Needle Peening Requirements:
 

• Supply air pressure between 552 and 758 kPa (80 and 110 psi) to the peening tool.
• Peening should performed as shown in Illustration 1. Peen the two fillets first (areas 1 and 2) in a side to side motion. Peen each fillet for approx. 1 minute. Peen the 'as cast' surface (area 3) last. Peen this area for 1 minute. Peening time should be approximately 3 minutes per cap.

• The peening angle should be approximately perpendicular to the cap. See Illustrations 7 and 8.
• Use the 9S-9082 turning tool to rotate the crankshaft so that counterweights do not interfere with access to the caps.

Peen Tool Maintenance:

In order to greatly extend the life of the 1930396 Peen Tool, the peen tool needs to be maintained periodically as listed below. Failure to follow the guidelines listed below will result in seizure of the peen tool piston

AFTER EVERY CAP PEENED

• Place a few drops of lightweight oil on the sidewalls of the peen tool piston bore.

• Disassemble the base of the peen tool and clean the piston and piston bore.
• Place a few drops of lightweight oil on the sidewalls of the peen tool piston and bore.

Needles may need to be replaced due to wear or breakage during the peening process. Replacement needles can be ordered from Ingersoll Rand or Chicago Pneumatic.
 
 

IMPORTANT NOTES:

• NEEDLES MUST BE CUT TO A FINAL LENGTH OF 71mm.
• NEEDLES MUST HAVE THE PEENING ENDS ROUNDED BEFORE USE

Needle Peening Procedure:

1. Position the crankshaft so that the counterweight radius is just past the main cap radius on the Holder?s side of the engine.
2. Turn the peening head at about a 15^o angle from perpendicular toward the Controller.
3. Peen the radius closest to the Controller for about one minute. Move across the entire width of the cap to cover the entire surface in the radius including the bevel.
4. Turn the peening head at about 15^o angle from perpendicular toward the Holder.
5. Peen the radius closest to the Holder for about one minute. Move across the entire width of the cap to cover the entire surface in the radius including the bevel.
6. Turn the peening head perpendicular (0^o angle) to the bottom of the main cap.
7. Peen the entire "as cast" surface (including bevels) first back and forth along the length of the cap and then back and forth along the width. Peening the bottom of the cap should take 1 to 1.5 minutes.
8. Inspect the main cap with the telescoping mirror to ensure complete coverage. Properly peened cap has the cast surface slightly deformed. The surface will appear lightly polished. See Illustration 6.
9. The main areas of concern are the roots of the fillet radii along the bottom of the cap shown in Illustration 5, item C. Ensure peening coverage over the edge of the bottom surface onto the bevel shown in Illustration 5, item A. 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.
10. Clean the main caps by wiping with a clean, oiled rag or some other method to remove any loose debris.
11. Wipe down the connecting rods, pistons, and bottom end of the liners with a clean, oiled rag to remove any loose debris.
12. Refill with oil and change oil and filters after 5 to 10 hours of operation. Cost of required oil change (i.e. oil, filters, disposal, and labor) after completion may be claimed at cost. Fuel to operate the engine may not be claimed.
13. Stamp 'D05' on the block adjacent to the serial number plate. The serial number plate is located on the left-hand side of the engine at the rear of the block.

Illustration 6 - Main Cap properly peened in the fillet radii.

 
 

Illustration 7 - Counterweight location during peening.

Illustration 8 - Controller guiding the peening head.

Magnaflux International Offices: http://www.magnaflux.com/

USA

3624 W. Lake Ave

Glenwood, IL 60025, USA

Phone: 847-657-5300

England

Faraday Rd, S.Dorcan Industrial Estate

Swindon, Wiltshire, SN3 5HE, England

Phone: 44-793-524566

India

5, SP Road, Begumpet

Hyderabad 500 016, India

Phone: 91-40-814892

Brazil

Rua Piratininga

235-Jardim Ruyce

09990-020-Diadema-SP, Brazil

Phone: 011-55-713-204
 

Spectronics/Spectroline: http://www.spectroline.com/

USA

956 Brush Hollow Rd

Westbury NY 11590, USA

Phone: 1-800-274-8888

Outside the USA Phone: 513-333-4840

Appendix B - Peen Tool Diagram