PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD VALVE ROTATOR ON CERTAIN G3520C GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD VALVE ROTATOR ON CERTAIN G3520C GENERATOR SETS

Usage:

SEBE8804

June 2, 2004
U-175
A-121
D-134
O-144

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD VALVE ROTATOR ON CERTAIN G3520C GENERATOR SETS
1100		PI30680

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30680" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI30680" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "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.

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COMPLETION DATE	TERMINATION DATE
December 31, 2004	June 30, 2005

PROBLEM

The cylinder head valve rotator needs to be inspected on certain G3520C Generators Sets. Due to a design tolerance stack up problem the cylinder head valve rotator could interfere with the valve bridge assembly. This could cause the bridge to contact the valve rotator, damaging both and leading the valve mechanism to fail. The engines need to be inspected, and adjusted if necessary.

AFFECTED PRODUCT

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Model

Identification Number

G3520C

B9P1-209 (engine serial numbers GHC1-163)

CWW1-213 (engine serial numbers GHE1-163)

CWY1-210 (engine serial numbers GDB1-48)

PARTS NEEDED

No parts are needed for this rework.

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	3	0	0	0	0
NOTE: This is a 3-hour job to inspect all cylinders. If rework is needed, an additional one hour per cylinder will be allowed. The number of cylinders that need to be reworked will vary.

PARTS DISPOSITION

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

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

Attach. (1-Owner Notification)
(2-Rework Procedure)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - The Cylinder Head Valve Rotator Needs To Be Inspected

MODELS INVOLVED - G3520C Generator Sets

Dear Caterpillar Product Owner:

The cylinder head valve rotator needs to be inspected on certain G3520C Generator Sets. Due to a design tolerance stack up problem the cylinder head valve rotator could interfere with the valve bridge assembly. This could cause the bridge to contact the valve rotator, damaging both and leading the valve mechanism to fail. The engines need to be inspected, and adjusted if necessary, on the products listed below. You will not be charged for the service performed.

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 June 2, 2004 when scheduling this service.

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)

Attached to June 2, 2004 Service Letter

Rework Procedure

Inspect and repair if necessary.

Using a .020-inch (or .5 mm) gage wire, place between the rotator and bridge. If the gage wire passes through the space the clearance is ok.
If the gage wire will not pass through the space:

Remove the rocker arm shaft assembly to remove the bridge assembly.

Using a die grinder, grind out a smooth radius on the underside of the bridge to provide clearance for the rotator.

Note: Do not grind more than .04 inch or 1 mm from the bridge profile.

Make sure the grind area is blended into the profile of the bridge so no rough edges are present, avoiding potential stress risers to initiate cracks.
Replace bridge and re inspect for allowed clearance. Confirm bridge adjustment is correct.
Reassemble rocker arm shaft and adjust valve lash to proper spec.