PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER HEADS ON G3520C LANDFILL ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER HEADS ON G3520C LANDFILL ENGINES

Usage:

REBE3850-00

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16Jul2008

U-375

A-303

O-340

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER HEADS ON G3520C LANDFILL ENGINES
1105 1100 1101 1052 1053		PS51521

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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 "PS51521" 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

31Jul2010

PROBLEM

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Some G3520C landfill engines are experiencing broken exhaust valves as a result of strain age cracking. All valve factures of this type occur on the valve stem 155mm to 170mm from the valve tip.

The new cylinder head incorporates a new exhaust valve with more uniform hardness. The new exhaust valve is robust against strain age cracking.

AFFECTED PRODUCT

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Model	Identification Number
G3520C	GZJ00161-00169, 174-186, 188, 196-198, 201, 204-210, 215, 217-307, 310-319, 321-376 GZK00161, 163-183 HAT00102, 200-205, 209-211 MAD00101-00102, 200-201

PARTS NEEDED

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Qty	Part Number	Description
1	5P3456	SEAL-O-RING
4	6V1903	SEAL-O-RING
2	6V5103	SEAL-O-RING
1	6V5134	SEAL-O-RING
1	7E2326	SEAL-RING
1	7W2221	RING-PISTON
1	8L9241	SEAL-O-RING
1	8N1234	RING-PISTON
1	8N4707	BAND-FILLER
1	9X7562	SEAL-O-RING
20	10R4703	HEAD GP-CYL
1	1077330	BEARING-CONN ROD
1	1547477	SEAL
1	2117826	LINER-CYLINDER
1	2434291	PLUG-SPARK
1	2540789	TURBO GP-BASIC (If Required)
1	2622061	BODY AS-PISTON
1	2623066	RING-PISTON TOP
4	2752604	FILTER AS-LUBE
20	2997609	KIT-GASKET(SCH)
40	3053447	SEAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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This program shall be applied after an exhaust valve failure has been experienced and the strain age crack is confirmed by the Caterpillar dealer. The program is to be applied if cylinder head group 269-0043 is currently installed on the engine and a valve failure occured with cylinder head part hours of less than 8000 hours.

To identify strain age cracking, measure from the tip of the valve to the fracture. Strain age cracks occur 155mm to 170mm from the valve tip. Additionally, strain age crack fractures exhibit intergranular core and transgranular rim characteristics as shown in Image 1.

After strain age cracking is confirmed, this program authorizes the repair of damaged components and the replacement of the remaining 19 cylinder heads on a prorated basis.

Note: This program cannot be applied to failures that occurred prior to the program release date.

Rework Procedure
1. Locate and remove the affected cylinder head and confirm that the valve stem fracture is due to strain age cracking.

2. Inspect turbocharger for damage. Replace only if damaged by exhaust valve failure.

3. Replace the components damaged by the exhaust valve failure.

4. Replace the 269-0043 cylinder head group with 10R-4307 cylinder head group on the remaining 19 cylinders.

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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%
0-8000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 25.0-hour job
After strain age cracking is confirmed, this program authorizes the following: For 269-0043 Cylinder Head part hours from 0 to 8000, Caterpillar Inc. pays 100% parts and labor for the after failure only repair of replacing damaged components. NOTE: If there has been a previous repair in which the customer participated, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and engine hours in the "Additional Comments" section of the warranty claim. Note: Components should only be replaced if damaged by the valve failure. For replacement of remaining cylinder heads on a before failure basis refer to the Pro-rate schedule shown in Image 1.1. Part age and hours apply on the before failure repair.

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