PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD LIFTING EYE BOLT HOLE ON VARIOUS 3508, 3512, AND 3516 ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD LIFTING EYE BOLT HOLE ON VARIOUS 3508, 3512, AND 3516 ENGINES

Usage:

REBE4694-00

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19Dec2008

U-658

A-546

D-560

O-600

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Priority Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD LIFTING EYE BOLT HOLE ON VARIOUS 3508, 3512, AND 3516 ENGINES
1100 1101		PI31607

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31607" 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 "PI31607" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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
30Jun2009	31Dec2009

PROBLEM

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One of the cylinder head lifting eye bolt holes needs to be inspected on various 3508, 3512, and 3516 engines. The affected cylinder head castings were poured using a certain pattern with a potential shift in the water passage core. This condition could result in penetration of the water jacket passage at this drilled hole location creating a coolant leak path into the rocker box and a subsequent oil dilution problem.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3508B	5PS00714-00754 6PN01166 S2B00632-00648, 650-655, 657-677, 679-680, 682-685 S2E00760-00777 ZAD00388-00390
3512B	2AF00724, 728 3ZW00994-01092 6GW01641-01649, 1652-1655 8RM00888-00892 FFG00069-00072 MHA00152 MKH00257 PWG00221-00230 S2H00414-00428 S2J00615-00652 S2L00802-00827, 829-830 ZAH00868-00920, 922-923, 925-926, 929-930 ZAJ00237-00239
3516B	7RN02054-02057 8NW01069, 1071-1076, 1078-1080, 1082 BCK00361-00373 FDX00490-00495 PAG00313-00327, 329-341, 343-344, 349, 352-353 PBR00601-00604, 606-612, 614, 616, 618 S2R00578-00616 S2S00459-00463 S2X01065-01102, 1104-1118, 1120, 1123-1126, 1128-1135, 1137-1138, 1140-1141, 1145-1146, 1149-1152, 1158, 1166, 1174, 1176 ZAP01118-01219, 1221-1238, 1240, 1242 ZAR00488-00525, 527, 530
PM3516B	BPD01258

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*****Group 2*****
3512	24Z10253-10281 49Y01148-01152 51Y00885 6WW01466-01479 PTH00786, 789-829 ZAF00608-00641, 643-648, 651-653, 656
3512B	PTM00648, 651
3516	8TW00591-00593, 605 ZAL00411-00426

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*****Group 3*****
3512	65Z01433-01448, 1453

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*****Group 4*****
3508B	S2A00145-00146 S2D00254-00255
3508C	LLC00194-00199 LLE00508-00525 TTA00245-00249 TTB00372-00375
3512	SBG00545-00566
3512B	4AW01750-01760, 1762-1763 PTF00607, 609-628, 632-636, 638-639 PTM01703-01819, 1821-1872 S2G00204-00221
3512C	E3W00200-00201 LLA01438-01618, 1620-1624, 1626-1630, 1632-1646, 1648-1657, 1659, 1662-1666, 1668-1669, 1671, 1674-1676, 1693, 1695-1696, 1698, 1714 LLF00287-00290 MLM00114-00122 R1A00312-00327 SLM00146-00149, 151-152 TTC00339-00352 TTF00292-00306, 308-310, 312-313
3516B	GZT00150 GZY00126-00128 S2P00208-00212, 214 S2T00108 S2W00133
3516B HD	S2Z00331-00339, 341-342, 346, 348
3516C	JTS00110-00115 PES00273-00283, 285-286 SBJ00687-00720, 722-732, 734-757, 759 SBK00703-00716 TTD00343 TTH00216-00221 TTJ00253-00262, 264-265

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*****Group 5*****
3508	68Z01360-01364 69Z00922
3512	67Z02260-02266 FDR00338-00342 PTG00349-00358, 360
3516	73Z00989

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
20	0102591	SETSCREW-SOCKET
1	2425328	HEAD AS-CYL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
20	0102591	SETSCREW-SOCKET
1	2425327	HEAD AS-CYL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 3*****
20	0102591	SETSCREW-SOCKET
1	2425326	HEAD AS-CYL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 4*****
20	0102591	SETSCREW-SOCKET
1	2993519	HEAD AS-CYL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 5*****
20	0102591	SETSCREW-SOCKET
1	2993518	HEAD AS-CYLINDER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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****Parts Stock ****

Refer to attached rework procedure for instructions on the plugging procedure for all affected cylinder heads in dealer parts stock. The affected cylinder heads are part numbers 154-1612, 290-1351, 172-0834, 295-2047, 172-0836 and are identifiable by 3 raised dots located near the outboard machined rail of the head (see image 1) and fall within the date range of 8/15/08 and 10/28/08. See image 2 for location of date stamp.

Parts that are reworked should be repackaged in original packaging and returned to dealer parts stock.

Image1

Image2

****Affected Product****

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Ensure the following items are included in the service technician's tool kit:
1. Brake cleaner
2. 3/16" Tee handle allen wrench
3. Blow gun with extension
4. Red Loctite-271 (CAT Part Number 155-0695)
5. Syringe with 1/8" tubing (as a suggested way of getting the right amount of loctite into the lifting eye hole)

Refer to the attached Rework Procedure for pictures and more details.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts reworked from dealer parts stock. A maximum of one hour may be claimed for inspection and an additional 0.5 hrs per reworked cylinder head.

****Affected Product****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 1
An additional 1.0 hours may be allowed per head if the Rocker box needs to be removed. An additional 4.0 hours may be allowed per head if the cylinder head needs to be replaced due to an observed coolant leak.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 2
An additional 1.0 hours may be allowed per head if the Rocker box needs to be removed. An additional 4.0 hours may be allowed per head if the cylinder head needs to be replaced due to an observed coolant leak.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 3
An additional 1.0 hours may be allowed per head if the Rocker box needs to be removed. An additional 4.0 hours may be allowed per head if the cylinder head needs to be replaced due to an observed coolant leak.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 4
An additional 1.0 hours may be allowed per head if the Rocker box needs to be removed. An additional 4.0 hours may be allowed per head if the cylinder head needs to be replaced due to an observed coolant leak.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 5
An additional 1.0 hours may be allowed per head if the Rocker box needs to be removed. An additional 4.0 hours may be allowed per head if the cylinder head needs to be replaced due to an observed coolant leak.

PARTS DISPOSITION

****Parts Stock****

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

****Affected Product****

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

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD LIFTING EYE BOLT HOLE ON VARIOUS 3508, 3512, AND 3516 ENGINES

MODELS INVOLVED - 3508, 3512, AND 3516 ENGINES

Dear Caterpillar Product Owner:

Certain identifiable cylinder heads need to be reworked on the products listed below. The existing cylinder head may leak and the proposed rework will replace any cylinder heads showing signs of a
coolant leak while proactively plugging the lifting eye hole that may potentially leak in the future. This procedure will in no way affect the performance and serviceability of your product. 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 19Dec2008 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 19Dec2008 Service Letter

Rework Procedure

The cylinder heads affected by this issue can be identified by 3 raised dots located near the outboard machined rail of the head (See image 1.1.1 & 1.1.2)

NOTE: Some dots may be round and easy to see while other may be less pronounced (see images 1.1.3)

Image1.1.1

Image1.1.2

Image1.1.3

If these dots are observed on any of the heads on the engine, follow the steps detailed below for each of the affected cylinder heads.

1. Remove the valve cover and look for signs of coolant buildup on the top of the cylinder head within the rocker box.

2. Check for oil emulsion (coolant traces in the oil) in the drilled 3/8-inch left hand side lifting eye hole that is located 38.10 mm (1.50 inch) left of the injector bore (See Image 1.2.1). If there are any signs of emulsion, the head will need to be replaced. If there is no sign of emulsion, proceed to next step.

Image1.2.1

3. Remove oil from the above mentioned bolt hole with a blow gun.

4. Fill bolt hole with brake cleaner.

5. Blow out hole with blow gun until hole is dry.

6. Look for signs of coolant seeping into the hole. If coolant starts to seep into the hole, replace the head; if bolt hole remains dry, proceed to the next step.

7. Carefully Place approximately 0.75 mL (cc) of Red Loctite-271 in the bottom of the bolt hole. A syringe with 1/8-inch tubing attached is a suggested method of getting the loctite into the hole. (see image 1.3.1)

8. Insert the set screw into the bottom end of the 3/16-inch T-handle allen wrench (see image 1.3.1)and then insert the set screw into the left hand side lifting eye hole. Torque set screw to 40N-m (30ft-lbs). A small piece of paper towel on the end of the allen wrench may help secure the set screw. (See image 1.3.2)

Image1.3.1

Image1.3.2

NOTE: In certain instances the set screw may not engage the bolt hole threads because of the proximity of the rocker box covering a small portion of the hole. If this situation occurs, the rocker box will need to be removed in order to install the set screw. Refer to the 3500 Disassembly and Assembly Guide for removal and installation instructions.

10. Re-install valve cover.

11. Torque valve cover bolts to 27 N-m. (20 lbf-ft)