PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER PACK IN CERTAIN G3516E, AND G3520E ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER PACK IN CERTAIN G3516E, AND G3520E ENGINES

Usage:

REBE4747-00

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09Feb2009

U-52

D-42

O-42

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER PACK IN CERTAIN G3516E, AND G3520E ENGINES
1215 1213 1216 1214		PS51625

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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 "PS51625" 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.

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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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TERMINATION DATE

28Feb2011

PROBLEM

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Certain G3516E, and G3520E engines have shown cylinder liner polishing near the top of the cylinder. Cylinder polishing itself is not a failure mode. However, heavy cylinder polishing in a particular cylinder can lead to single cylinder detonation because of the loss of oil control. Loss of oil control leads to the presence of oil during combustion or increased deposit levels in the cylinder.

Heavy polishing, loss of oil control, and detonation may not result in a significant increase in oil consumption unless the detonation occurs in mulitple cylinders.

Overall engine oil consumption, blowby, and cylinder compression are determining factors for scheduling an in-frame overhaul. Several cylinders experiencing heavy liner polishing may lead to an in-frame overhaul interval shorter than specified in the Operation and Maintenance Manual (SEBU7681).

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
G3516E	GAS00111-00233 SLY00106-00109
G3520E	GZH00111-00133 HAL00100-00102

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*****Group 2*****
G3520E	GZG00111 SXY00100-00102

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
3	7N2046	SEAL-O-RING
1	7W2221	RING-PISTON
1	8N1234	RING-PISTON
1	8N4707	BAND-FILLER
1	1077330	BEARING-CONN ROD
1	1111349	GASKET
1	2117826	LINER-CYLINDER
1	2456770	COVER
1	2600135	TUBE AS-OIL JET
1	2622063	BODY AS-PISTON
1	2719135	COVER
1	2997609	KIT-GASKET(SCH)
1	3094046	RING-PSTN-TOP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% 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*****
3	7N2046	SEAL-O-RING
1	7W2221	RING-PISTON
1	8N1234	RING-PISTON
1	8N4707	BAND-FILLER
1	1077330	BEARING-CONN ROD
1	1111349	GASKET
1	2117826	LINER-CYLINDER
1	2456770	COVER
1	2600135	TUBE AS-OIL JET
1	2622065	BODY AS-PISTON
1	2997609	KIT-GASKET(SCH)
1	3094046	RING-PSTN-TOP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% 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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The most common repair is replacement of the cylinder pack on a single cylinder if no other cause can be found for repeated single cylinder detonation warnings or detonation shutdowns.

NOTE: Prior to applying this program on single cylinder detonation, proper detonation trouble shooting needs to be performed. Perform all appropriate detonation troubleshooting for that cylinder. Refer to Troubleshooting Guide, "Detonation Occurance". Verify that the ignition system, detonation system, engine wiring, and valve lash are not the cause of the detonation alarms. It is also important to ensure that the engine is applied properly, for example rated for fuel, altitude, and ambient conditions. Use the appropriate Troubleshooting Manual for this step.

After 3 single cylinder pack replacements have been peformed due to detonation on those particular cylinders, all remaining cylinder packs should be replaced.

Use a boroscope to verify cylinder liner polishing is occuring prior to replacing the cylinder pack. A significant loss of crosshatch near top ring turn-around, wear step, and/or shiny polished appearance indicate heavy liner polishing. Refer to Image1 for an example of heavy liner polishing.

Monitor and trend oil consumption, blowby, and cylinder compression per guidelines in the Operation and Maintenance Manual (SEBU7681). The trends developed for these three conditions are used in determining when the engine has reached an in-frame overhaul interval. If the guidelines in the Operation and Maintenance Manual are met, all cylinder packs will need replaced.

NOTE: If multiple cylinder packs are replaced the parts quantities should be adjusted accordingly.

Fully read and understand the rework procedure prior to applying this program or ordering replacement parts.

NOTE: The piston body may not require replacement. Refer to reuse guidelines and part number details in the attached Rework Procedure.

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Image1

SERVICE CLAIM ALLOWANCES

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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%
*****Group 1*****
0-8000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
8001-15000 hrs, 49-96 mo	75.0%	75.0%	0.0%	0.0%	25.0%	25.0%
15001-30000 hrs, 97-144 mo	50.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 10.0-hour job for Group 1
An additional 8 hours labor will be allowed for each additional cylinder pack replaced.

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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%
*****Group 2*****
0-8000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
8001-15000 hrs, 49-96 mo	75.0%	75.0%	0.0%	0.0%	25.0%	25.0%
15001-30000 hrs, 97-144 mo	50.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 10.0-hour job for Group 2
An additional 8 hours labor will be allowed for each additional cylinder pack replaced.

PARTS DISPOSITION

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

Rework Procedure

Refer to appropriate service manual as necessary.

NOTE: If this is the 3rd cylinder that has been replaced due to heavy liner polishing, then all remaining cylinder liners should be replaced following this rework procedure.

NOTE: If oil consumption, blowby, and/or cylinder compression has exceeded the guidelines in the Operation and Maintenance Manual (SEBU7681) for In-frame Overhaul, then all cylinder liners should be replaced. Document the trends for these three parameters.

Procedure:

1) Verify and document single cylinder detonation of a particular cylinder by capturing logged events from Caterpillar Electronic Technician.

2) Perform all appropriate detonation troubleshooting for that cylinder. Refer to Troubleshooting Guide, "Detonation Occurance". Verify that the ignition system, detonation system, engine wiring, and valve lash are not the cause of the detonation alarms. It is also important to ensure that the engine is applied properly, for example rated for fuel, altitude, and ambient conditions. Use the appropriate Troubleshooting Manual for this step.

3) Use a boroscope to verify cylinder liner polishing is occuring prior to replacing the cylinder pack.

Note: Follow Dissassembly and Assembly Manual for the appropriate removal and installation procedures. Cleanliness is an important factor. The exterior components should be thoroughly cleaned before beginning the dissassembly procedure. This will help prevent dirt from entering the internal mechanism. Precision components can be damaged by contaminants and/or by dirt. Keep components covered and protected at all times.

4) Remove the single cylinder pack experiencing detonation.

5) Verify the piston part number is one of the following: 262-2061, 262-2063 or 262-2065. If it is not, the piston will need replaced. The information below will help to identify the correct piston part number for your application.

Appropriate piston part numbers:
For G3516E and G3520E 1500 rpm use 262-2063 piston.
For G3520E 1200 rpm use 262-2065 piston.

NOTE: For engines containing old piston part numbers, the new pistons (262-206X) and the old pistons can be in the same engine. Dimensions and weights are the same. If a new piston is to be installed in a cylinder where an old piston was removed, the piston oil jet for that cylinder will need to be replaced with the 260-0135 oil jet.

For single cylinder replacements of the old piston with a new piston (262-206X) and oil jet, it is not necessary to install the new oil pump relief cover. If this program is being performed to replace all cylinder packs and oil jets in the engine to the new part number, the oil pump relief cover should also be replaced with the appropriate cover:

Appropriate oil pump relief cover part numbers:
For G3516E use 245-6770 Cover.
For G3520E use 271-9135 Cover.

6) If a piston is to be reused, clean the piston and ensure that it meets reusability guidelines.

7) Remove and replace the polished cylinder liner.

8) If necessary, replace the oil jet as directed in Step 5.

9) Install the cylinder pack ensuring that the new 309-4046 top ring is used.

10) If necessary, replace the oil pump relief cover with the appropriate cover.

11) Start and load engine to 100% load. Using Caterpillar ET, verify that detonation is not present on the cylinder repaired. After 1 hr of run time, reset valve lash on the cylinder replaced.