PRODUCT SUPPORT PROGRAM FOR RESETTING THE VALVE LASH ON CERTAIN C-15 AND C-16 ENGINES IN COMMERCIAL AND ON-HIGHWAY TRUCK APPLICATIONS, AND IN CERTAIN 3406E COMMERCIAL APPLICATIONS

Usage:

SEBE7977

May 3, 2002
U-89
A-64
AU-58
S-58
H-58
O-76
TT-2

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR RESETTING THE VALVE LASH ON CERTAIN C-15 AND C-16 ENGINES IN COMMERCIAL AND ON-HIGHWAY TRUCK APPLICATIONS, AND IN CERTAIN 3406E COMMERCIAL APPLICATIONS
1105		PS40970

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 "PS40970" 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.

TERMINATION DATE

December 31,2002

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 at the first oil change unless there is a customer complaint of low power or noise in the engine overhead. If this occurs the repair should be made as soon as possible.

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-15 Truck	6NZ61645-6NZ62219
C-16 Truck	7CZ2972-7CZ3021
C-15 Industrial	BEM778-BEM809
C-16 Industrial	BFM377-BFM379
3406E Industrial	6BR2397-6BR2402
3406E Marine	9WR2588?9WR2615

PARTS NEEDED

No parts needed NOTE: Valve cover seals should be 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
2.5	2.1	1.8	1.9

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts see note	Labor Hrs see note	Parts	Labor Hrs	Parts	Labor Hrs
Based on Operator noise/power complaint	100%	100%	0	0	0	0
At regular oil change	100%	50%	0	0	0	0
NOTE: For all non-truck applications this is a 1.8- hour job. NOTE: If engine is brought in, or visited, with an overhead noise or low power complaint, 100% of the labor cost of the valve lash / Injector Height / Compression Brake adjustment will be paid. If operating time on an engine is less than 10,000 miles / 16,000 km / 300 hours then this cannot be counted as a first overhead adjustment and the work will need to be performed again in the regular maintenance interval. If the operating time exceeds 10,000 miles / 16,000 km / 300 hours, then this service may be counted as the first maintenance adjustment. NOTE: If the engine is brought in, or visited, for a regular oil change, then this service should be performed and 50% of the valve lash / Injector Height / Compression brake adjustment labor will be paid. The only exception to this is if the engine is a Marine Engine. Marine engines will remain paid at 100% labor hours. NOTE: In a few cases proactive inspection of the valve lash may have occurred prior to the issuance of this Service Letter. Dealer Representatives were informed on 2/20/02 that the valve lash check/adjustment should wait until the first regular oil change, unless there was an overhead noise or power complaint. Claims with repair dates on or before 3/1/02 will be paid at the 100% labor rate. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

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.
Adjust Valve Lash, (Both Inlet and Exhaust) Injector Height, and Compression Brake per normal procedure specified in the Engine Service Manual. For reference, the standard valve lash, injector height and compression brake specifications are:

Valve Lash Setting Specifications:

Inlet = 0.38 mm (0.015 inch)
Exhaust = 0.76 mm (0.030 inch)
Valve Adjusting Nut Torque = 30+ 7 N·m (22 + 5 lb ft)

Injector Height Setting Specifications:

Injector Height = 78.0 + 0.2 mm (3.07 + 0.01 inch)
Injector Adjusting Nut Torque = 100 + 10 N·m (74 + 7 lb ft)

NOTE: If engine is equipped with an engine compression brake, loosen the adjusting screw for the lash on the slave piston for the compression brake prior to adjusting the engine valve lash. Follow the manufacturers procedure for re-adjusting slave piston lash. For reference the standard slave piston lash specifications are listed in the tables below.

Jake Brake Slave Piston Lash Specifications:

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Jake Brake
Slave Piston Lash Setting
Engine	Setting	Feeler Gauge
3406E	0.84 mm (0.033 inch) for 435 h.p. and above	1555238
3406E	0.94 mm (0.037 inch) below 435 h.p.	1555239
3456	0.84 mm (0.033 inch)	1555238
C-15	0.84 mm (0.033 inch) for 435 h.p. and above	1555238
	0.94 mm (0.037 inch) below 410 h.p.	1555239
	0.84 mm (0.033 inch) for 375/435 h.p. Multitorque rating	1555238
C-16	0.94 mm (0.037 inch)	1555239

Pac Brake Slave Piston Lash Specifications:

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Engine	Setting
C-15	0.76 mm (0.030 inch)
C-16	0.76 mm (0.030 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.