PRODUCT SUPPORT PROGRAM FOR REPAIRING A VALVE FAILURE ON CERTAIN G3508B, G3512B, G3516, AND G3516B GAS ENGINES
Usage:
REBE8622-01
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| 25Oct2012 |
| (Revised 31Jan2014) |
U-562
A-444
D-479
O-518
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| After Failure Only | PRODUCT SUPPORT PROGRAM FOR REPAIRING A VALVE FAILURE ON CERTAIN G3508B, G3512B, G3516, AND G3516B GAS ENGINES |
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| 1100 1225 1209 1123 1102 1121 1052 | PS52318 |
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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 "PS52318" 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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| NOTE: | This Revised Service Letter replaces the 25Oct2012 Service Letter. Changes have been made to the Parts Needed and Action Required. |
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TERMINATION DATE |
| 31Oct2014 |
PROBLEM
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| The existing 104-7184 Valves can experience strain age cracking on certain G3508B, G3512B, G3516, and G3516B Gas Engines in a Ultra Lean Burn (ULB) or a Landfill application. If the existing valve fails, it may damage turbocharger and the associated cylinder pack. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| G3516B | JEF00101-00189, 1001-1730 |
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| *******Group 2******* | |
| G3512B | JHH00100-00102, 1001-1022 |
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| *******Group 3******* | |
| G3508B | RBK00101-00109, 1001-1160 |
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| *******Group 4******* | |
| G3516 | 4EK00114, 116, 276, 283, 344, 347-348, 355, 372, 437, 479, 522-523, 525-526, 540, 557, 575, 577, 580, 609, 661, 663-664, 666, 752, 754, 794, 835-836, 838, 1065-1066, 1069-1070, 1324-1326, 1366, 1368-1369, 1373, 1378, 1469, 1488, 1490, 1496, 1498, 1537-1538, 1543, 1546, 1551-1552, 1562, 1601, 1605, 1715, 2396, 2400, 2402, 2485, 2494, 2538, 3085-3086, 3088-3090, 4393, 4466, 4471, 4514, 4516-4517, 4590, 4596, 4842, 4860, 4953, 5151, 5223, 5226, 5284 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 16 | 0R2881 | HEAD GP-CYL BSC |
| 16 | 5N2126 | CONNECTOR |
| 1 | 10R9264 | CYLINDER PACK AS |
| 1 | 1077330 | BEARING-CONN ROD |
| 1 | 2720759 | SEAL-PIP |
| 1 | 3348759 | TURBO GP-BASIC |
| 16 | 3550764 | KIT-GASKET(SCH) |
| 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. |
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| *******Group 2******* | ||
| 12 | 0R2881 | HEAD GP-CYL BSC |
| 12 | 5N2126 | CONNECTOR |
| 1 | 10R9264 | CYLINDER PACK AS |
| 1 | 1077330 | BEARING-CONN ROD |
| 1 | 2720759 | SEAL-PIP |
| 1 | 3479366 | TURBO GP-BASIC |
| 12 | 3550764 | KIT-GASKET(SCH) |
| 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******* | ||
| 8 | 0R2881 | HEAD GP-CYL BSC |
| 8 | 5N2126 | CONNECTOR |
| 1 | 10R9264 | CYLINDER PACK AS |
| 1 | 1077330 | BEARING-CONN ROD |
| 1 | 2720759 | SEAL-PIP |
| 1 | 3348759 | TURBO GP-BASIC |
| 8 | 3550764 | KIT-GASKET(SCH) |
| 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. |
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| *******Group 4******* | ||
| 16 | 0R3678 | HEAD GP-CYL 60 HZ (if required) |
| 16 | 0R3680 | HEAD GP-CYL 50 HZ (if required) |
| 1 | 0R4449 | CYLINDER PACK AS |
| 16 | 5B7890 | PLUG-PIPE |
| 1 | 1077330 | BEARING-CONN ROD |
| 1 | 1712326 | TURBO GP-BASIC |
| 1 | 2720759 | SEAL-PIP |
| 16 | 3550763 | KIT-GASKET(SCH) (if required) |
| 16 | 3550764 | KIT-GASKET(SCH) (if required) |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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. |
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ACTION REQUIRED
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| Replace the damaged head with heads that include more robust valves that improve durability against strain age cracking. Inspect the turbocharger and replace if damaged by foreign material resulting specifically from valve failure. The nozzle valve and turbine wheel would see severe damaged if foreign material enters the turbine inlet. Inspect cylinder pack for damage and replace if necessary. Typical cylinder pack damage would be scored liners, damaged piston rings, or inclusions on the piston. Recommend changing all other heads to ones that include the new valves upon first failure. Ensure 307-4641 Exhaust Valves are in the heads if updating a ULB engine. Ensure 308-9177 Exhaust Valves are in the heads if updating a landfill engine. If the turbocharger is damaged and requires replacement, retain the old turbocharger. Do not replace the turbocharger if it is not damaged. Refer to the Parts Disposition. For Group 4, select the appropriate gasket kit based on type of exhaust manifold on engine. If using a water cooled exhaust manifold, use the 355-0763 Gasket Kit. If using a bellows style exhaust manifold, use the 355-0764 Gasket Kit. |
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SERVICE CLAIM ALLOWANCES
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