PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER HEADS ON CERTAIN G3408B AND G3408C SPARK IGNITED ENGINES

Usage:

SEBE8516-01

September 25, 2003
(Revised March 2004)
U-260
A-185
D-190
O-220

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER HEADS ON CERTAIN G3408B AND G3408C SPARK IGNITED ENGINES
1105		PS50601

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 "PS50601" 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.

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 September 25, 2003 Service Letter. Changes have been made to the Parts Needed.

TERMINATION DATE

September 30, 2005

PROBLEM

Cylinder heads have been experiencing short exhaust valve life due to excessive wear, radial cracks, and or valve fracture. New cylinder heads need to be installed on certain G3408B and G3408C engines.

AFFECTED PRODUCT

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Model

Identification Number

G3408B

6NB1-2500

6RJ1-92

G3408C

3WR1-506

BAZ1-200

6FW1-315

PARTS NEEDED

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Qty	Part Number	Description
1	10R1137	HEAD GP
1	2261800	CONVERSION KIT
1	2261801	CONVERSION KIT
1	2261802	CONVERSION KIT

NOTE: 6NB and 6RJ will use conversion kit 2261800.

NOTE: 3WR, BAZ, and 6FW could use either 2261801(standard EIS ignition) or 2261802 (EIS-CSA, Canadian Standard Association, ignition).

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Part smu	Caterpillar		Dealer Suggested		Customer Suggested
Part smu	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
* G3408B (6NB, 6RJ)*
0-4000	100%	8.0	0	0	0	0
4001-6000	70%	5.6	0	0	30%	2.4
6001-8000	50%	4	0	0	50%	4
8001-10000	30%	2.4	0	0	70%	5.6
*** G3408C (3RW, BAZ, 6FW)
0-6000	100%	8	0	0	0%	0
6001-8000	70%	5.6	0	0	30%	2.4
8001-10000	50%	4	0	0	50%	4
10001-12000	30%	2.4	0	0	70%	5.6
NOTE: This is an 8.0?hr job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

Replace current cylinder head with the improved cylinder head and peripheral hardware. Replacement of the cylinder head is necessary if:

The current cylinder head experiences exhaust valve recession of 0.070".

Radial cracking of the exhaust valve is observed.

An exhaust valve fractures and the valve drops into the cylinder.

If a failure occurs on one cylinder head only replace that cylinder head. The kits are set up to work one cylinder head at a time so if both cylinder heads need replacing two kits will need to be ordered. If you are replacing a cylinder head on an EIS engine (3WR, BAZ, or 6FW serial prefix) the conversion kit will have an addition kit to rebuild the ignition transformers. Be sure to order the correct conversion kit for your engine. NOTE: This program is based on piece part hours and not product hours.