PRODUCT SUPPORT PROGRAM FOR RESETTING VALVE LASH ON CERTAIN C-10 AND C-12 ENGINES IN ON-HIGHWAY TRUCK AND COMMERCIAL APPLICATIONS, AND IN CERTAIN 3196 MARINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR RESETTING VALVE LASH ON CERTAIN C-10 AND C-12 ENGINES IN ON-HIGHWAY TRUCK AND COMMERCIAL APPLICATIONS, AND IN CERTAIN 3196 MARINE ENGINES

Usage:

SEBE7949-01

March 23, 2002
(Revised May, 2002)
U-66
AU-42
S-42
H-42
O-54
TT-2
TM-3

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR RESETTING VALVE LASH ON CERTAIN C-10 AND C-12 ENGINES IN ON-HIGHWAY TRUCK AND COMMERCIAL APPLICATIONS, AND IN CERTAIN 3196 MARINE ENGINES
1105		PS40914

NOTE: This Program can 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 "PS40914" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, 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 March 23, 2002 Service Letter. Changes have been made to the Mail Codes to add TM-3.

TERMINATION DATE

March 31, 2003

PROBLEM

Engines within the specified ranges may have mis-adjusted valve lash settings and/or low torque on the valve lash adjusting screw jam nut. This program is to cover resetting the valve lash on those engines as soon as possible to avoid possible engine damage.

AFFECTED PRODUCT

NOTE: The serial number ranges listed below reflect the entire range of engines suspect for this problem. However, a significant number of these engines were inspected and/or reset either at Caterpillar or the OEM factory. Those engines were marked with the letters "YD" stamped near the serial number plate on the cylinder block. Engines already marked "YD" are not affected by this Service Letter.

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Model	Identification Number
C-10 Truck	3CS24644-24790
C-12 Truck	2KS77195-77632 9SM2294-2370 9NS20382-20396
C-10 Industrial	BCX483-511
C-12 Industrial	BDL627-703
3196 Marine	2XR4639-4661

PARTS NEEDED

No parts needed NOTE: Valve cover seals should reused.

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

For Truck Engine applications, claim as follows: Code 1105-025, Inlet / Exhaust Valve(s) Adjust. Allowable times per chassis are as follows:

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SC	MC	CV	CO
2.4	1.9	1.7	1.9

For all other applications, claim as follows:

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-40000 0-12 mos	100%	2	0	0	0	0
NOTE: This is a 2.0?hr job.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. Attach. (1-Rework Procedure)

Rework Procedure

Inspect the serial number plate area on the cylinder block (right rear corner of block) to determine if the letters "YD" are stamped on the block. If stamped "YD", then the engine has already been reworked and no further action is necessary. If there is no "YD" stamp, proceed with the rework procedure.
Visually inspect the valve rocker arms to see if there are any loose or missing adjusting screw jam nuts. If any nuts are missing, locate and retrieve the missing nut(s). Do not reuse any nuts that may have backed off; replace as necessary.
Depending on the miles/hours on the engine, identify the extent of service required as follows:

For affected engines with LESS than 10,000 miles / 16,000 km / 300 hours, only valve lash adjustment is required. For these low hour engines, the normal complete overhead adjustment maintenance must still be performed on schedule as specified in the Engine Operation and Maintenance Manual.

For engines over 10,000 miles / 16,000 km / 300 hours, the normal COMPLETE overhead adjustment (including valves, injectors, and Jake Brake) should be performed under this PSP. In this case, this initial adjustment will suffice for the normal first scheduled overhead lash adjustment. The normal published maintenance schedule should be followed thereafter, for the second overhead lash adjustment and beyond.

Adjust Valve Lash (Both Inlet and Exhaust) per normal procedure specified in the Engine Service Manual. For reference, the standard valve lash specifications are:

Valve Lash Setting Specifications:

Inlet = 0.38 mm (0.015 inch)
Exhaust = 0.64 mm (0.025 inch)
Valve Adjusting Nut Torque = 25+ 7 N·m (18 + 5 lb ft)

NOTE: Removal of Jake Brake housings (if equipped) is not required for valve lash adjustment only on low-hour engines. However, if the Jake Brakes are removed they should be re-adjusted ? note that the lash settings are different for C-10 and C-12 engines. The specifications are:

Jake Brake Slave Piston Lash Specifications:

C-10 0.64 mm (0.025 inch)
C-12 1.02 mm (0.040 inch)

When the procedure is complete, stamp the letters "YD" to the right of the engine serial number plate on the cylinder block to verify that this rework has been completed.