PRODUCT SUPPORT PROGRAM FOR REPAIRING AN OUTER VALVE SPRING FAILURE ON VARIOUS 3508, 3512 AND 3516 PETROLEUM ENGINES Caterpillar


PRODUCT SUPPORT PROGRAM FOR REPAIRING AN OUTER VALVE SPRING FAILURE ON VARIOUS 3508, 3512 AND 3516 PETROLEUM ENGINES

Usage:

REBE7753-01

07Dec2011
(Revised 23Jan2012)


U-545
A-446
D-476
O-478

 

After Failure Only

  
  

PRODUCT SUPPORT PROGRAM FOR REPAIRING AN OUTER VALVE SPRING FAILURE ON VARIOUS 3508, 3512 AND 3516 PETROLEUM ENGINES

1100
PS52139
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 "PS52139" 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 07Dec2011 Service Letter. Changes have been made to the Affected Product.


TERMINATION DATE

30Jun2013

PROBLEM

The existing outer valve spring can fail on various 3508, 3512 and 3516 Petroleum Engines.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
3512 65Z01407

67Z02246
3512B 4AW01745

BLF00190

PTF00504

S2G00169

S2K00182

S2N00116
3512C LLA01262

LLF00270
*******Group  2*******
3512 49Y01135

51Y00862

6WW01307

CMJ01753

PTH00683

ZAF00363
3512C  SBG00338
*******Group  3*******
3512B 6GW01528

8RM00852

FDE00425

MHA00135

PTM01318

S2H00384

S2J00334

S2L00549

ZAH00640

ZAJ00143
*******Group  4*******
3512B  2AF00712
*******Group  5*******
3512C  R1A00304
*******Group  6*******
3516  73Z00979
3516B GZT00126

GZX00112

LEK00150

S2P00138
*******Group  7*******
3516 25Z07119

27Z00918

29Z01456
*******Group  8*******
3516B  2JW00416
*******Group  9*******
3508 23Z08026-08029

5PW00867-00883, 890-909

68Z01357-01364

70Z01082-01091

95Y01349-01366

96Y02156-02159

CNF00739-00749
*******Group  10*******
3508B 5KW01963-02039, 2041-2109, 2111-2123, 2126-2285

6PN00973-01166

BPX00115-00138

CBB00576-00577

CNB01706-01767

S2A00128-00156

S2B00564-00708

S2D00219-00255

ZAD00336-00392
3508C LLC00189-00199

LLE00480-00534
*******Group  11*******
3512 49Y01136-01152

51Y00863-00885

65Z01408-01462

67Z02247-02294, 6324

6WW01308-01311, 1313-1479

CMJ01754-01762

PTG00334-00360

PTH00684-00829

ZAF00364-00661
3512B 2AF00713-00734

4AW01746-01769

6GW01529-01655

8RM00853-00892

BLF00191-00194

FDE00426-00454

MHA00136-00152

PTF00505-00643

PTM01319-01836, 1847-1856, 1859-1872, 1878-1880

S2G00170-00233

S2H00385-00437

S2J00335-00672

S2K00183-00321

S2L00550-00846

S2N00117-00128

ZAH00641-00935

ZAJ00144-00239
3512C LLA01263-01860

LLF00271-00300

R1A00305-00334

SBG00339-00582
*******Group  12*******
3516 25Z07120-07125

27Z00919-00922

29Z01457-01465, 1698

73Z00980-00989

8TW00464-00480, 483, 496, 529, 535-595, 605

GZR00137-00279

ZAL00175-00429
3516B 1NW00158-00161

2JW00417-00421

7RN01991-02040

8NW00997-01080

9AN00409-00411

CAN00135-00137

FDX00416-00495

GAR00191-00202

GZS00738-00894

GZT00127-00150

GZX00113-00121

LEK00151-00153

PAG00200-00377

PBR00168-00633

S2P00139-00223

S2R00508-00636

S2S00295-00463

S2W00107-00134

ZAP00774-00881, 883-1295

ZAR00348-00542
3516B HD  S2Z00281-00356
3516C PES00224-00314

SBK00429-00502, 700-732
PM3516B  BPD01200-01268

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
48 2A4429 LOCK-RETAINER
48 1977055 LOCK-RETAINER
48 3165976 SPRING
48 3165977 SPRING-VALVE
24 3165978 ROTOCOIL AS
24 3165979 ROTOCOIL AS
24 3165980 SEAL
24 3165981 WASHER
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.
*******Group 2*******
12 10R8844 HEAD GP-CYL BSC
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.
*******Group 3*******
12 10R7765 HEAD GP-CYL BSC
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.
*******Group 4*******
12 10R7765 HEAD GP-CYL BSC
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.
*******Group 5*******
48 2A4429 LOCK-RETAINER
48 1977055 LOCK-RETAINER
48 3165976 SPRING
48 3165977 SPRING-VALVE
24 3165978 ROTOCOIL AS
24 3165979 ROTOCOIL AS
24 3165980 SEAL
24 3165981 WASHER
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.
*******Group 6*******
64 2A4429 LOCK-RETAINER
64 1977055 LOCK-RETAINER
64 3165976 SPRING
64 3165977 SPRING-VALVE
32 3165978 ROTOCOIL AS
32 3165979 ROTOCOIL AS
32 3165980 SEAL
32 3165981 WASHER
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.
*******Group 7*******
16 10R8844 HEAD GP-CYL BSC
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.
*******Group 8*******
16 10R7765 HEAD GP-CYL BSC
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.
*******Group 9*******
32 2A4429 LOCK-RETAINER
32 1977055 LOCK-RETAINER
32 3165976 SPRING
32 3165977 SPRING-VALVE
16 3165978 ROTOCOIL AS
16 3165979 ROTOCOIL AS
16 3165980 SEAL
16 3165981 WASHER
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.
*******Group 10*******
32 2A4429 LOCK-RETAINER
32 1977055 LOCK-RETAINER
32 3165976 SPRING
32 3165977 SPRING-VALVE
16 3165978 ROTOCOIL AS
16 3165979 ROTOCOIL AS
16 3165980 SEAL
16 3165981 WASHER
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.
*******Group 11*******
48 2A4429 LOCK-RETAINER
48 1977055 LOCK-RETAINER
48 3165976 SPRING
48 3165977 SPRING-VALVE
24 3165978 ROTOCOIL AS
24 3165979 ROTOCOIL AS
24 3165980 SEAL
24 3165981 WASHER
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.
*******Group 12*******
64 2A4429 LOCK-RETAINER
64 1977055 LOCK-RETAINER
64 3165976 SPRING
64 3165977 SPRING-VALVE
32 3165978 ROTOCOIL AS
32 3165979 ROTOCOIL AS
32 3165980 SEAL
32 3165981 WASHER
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

There are two different repair actions in this program depending if there is a remanufactured cylinder head available for the engine. The Affected Product and associated Parts Needed have been divided into groups specific to the repair.

No Remanufactured Cylinder Head Available:
If a broken outer valve spring is found, all of the valve springs packs on the engine should be replaced. This action can be done without removing the cylinder heads from the engine by bringing the piston to top dead center and removing the rotator and keepers. Pressurizing the cylinder may be required. New inner and outer springs, rotators, exhaust valve spring washers, inlet valve stems seals and keepers should be used when reassembling.

Remanufactured Cylinder Head available:
For engine with a remanufactured cylinder head available, replace the existing cylinder head on each cylinder with a remanufactured cylinder head. This work should be completed only after inspecting the top end and determining no other engine damage has occurred.

Refer to appropriate Service Manual as required.

NOTE: If the valve has made piston contact the cylinder pack and cylinder head should be replaced.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-11000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 40.0-hour job for Group 1

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-9000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 40.0-hour job for Group 2

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-9000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 40.0-hour job for Group 3

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 4*******
0-4000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 40.0-hour job for Group 4

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 5*******
0-4000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 40.0-hour job for Group 5

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 6*******
0-11000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 50.0-hour job for Group 6

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 7*******
0-9000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 50.0-hour job for Group 7

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 8*******
0-9000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 50.0-hour job for Group 8

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 9*******
0-11000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 30.0-hour job for Group 9

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 10*******
0-11000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 30.0-hour job for Group 10

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 11*******
0-11000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 40.0-hour job for Group 11

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 12*******
0-11000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 50.0-hour job for Group 12



PARTS DISPOSITION

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

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