PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE CYLINDER HEADS ON CERTAIN G3512C, G3512E, G3516C, G3520C, AND G3520E ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE CYLINDER HEADS ON CERTAIN G3512C, G3512E, G3516C, G3520C, AND G3520E ENGINES

Usage:

TEBE1147-01

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16May2014

(Revised 10Jul2014)

U-280

A-210

D-251

O-242

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE CYLINDER HEADS ON CERTAIN G3512C, G3512E, G3516C, G3520C, AND G3520E ENGINES
1105 1100		PI32343

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32343" 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 "PI32343" 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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NOTE:	This Revised Service Letter replaces the 16May2014 Service Letter. Changes have been made to the Affected Product.

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COMPLETION DATE	TERMINATION DATE
30Nov2014	31May2015

PROBLEM

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The cylinder heads need to be inspected and possibly reworked on certain G3512C, G3512E, G3516C, G3520C, and G3520E Engines. The existing 3327386 Rotocoil Assembly can fail internally resulting in a loss of rotation of the valve.

AFFECTED PRODUCT

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Model	Identification Number
G3512E	GFM00115 NGS00130-00162 SSR00150-00157, 159-225
G3516C	F6D00101-00108 F6E00101 F6F00101-00107 GSB00113-00127 GZC00211-00249, 251-259 GZZ00114-00173, 180-362 TJB00101-00109 TJC00817-00819
G3516E	F6G00101-00102 GAS00111-00280 SLY00106-00109
G3520C	B9P00101-00104, 200-214 CWW00100-00131, 200-301 CWY00100-00104, 200-221 GZA00191-00258 GZB00201-00231, 233-249 GZJ00161-00553, 600-662 GZK00151-00183 GZL00141-00146 GZM00131-00214 GZN00211-00251, 253-254, 257, 261-451, 454-880 HAT00102, 200-211 HEA00101-00102 HEB00103-00104 LGS00150-00176 MAD00101-00102, 201 RLP00150-00261
G3520E	GZE00110-00216, 218-241 GZG00111 GZH00111-00167 HAL00100-00102 SXY00100-00102

PARTS NEEDED

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Qty	Part Number	Description
1	9Y6792	GASKET-SPARK
1	2037859	GASKET
4	3165978	ROTOCOIL AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 35% 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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Check the engine's service records.

Determine if the engine has received service and the following cylinder heads were installed between June 2013 and February 2014. Part numbers: 10R4565, 10R4703, 10R7927, 10R7928, 4155584, 4155585

If the engine has not received service and the above cylinder heads were not installed, then no further action is required.

If the engine has received service and the above cylinder heads were installed, then inspect each of the engine's cylinder heads.

Remove the valve cover and inspect the rotocoils for tabs. Refer to Image 1.1.1 and Image 1.2.1 in the Rework Procedure.

If a cylinder head is equipped with rotocoils with no visible tabs (316-5978), then no further action is required. Install the valve cover.

If a cylinder head equipped with rotocoils with tabs (332-7386), then replace the rotocoils.

The correct rotocoil part number is 316-5978 to directly replace old rotocoil part 332-7386. Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 0.5-hour job
0.5 Hour to inspect the engine's records. If necessary, an additional 2.0 Hours is allowed to inspect the engine's cylinder heads. If necessary, an additional 1.0 Hour is allowed to rework each cylinder head to replace the rotocoils. The parts and rework labor are to repair one cylinder head.

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE CYLINDER HEADS ON CERTAIN G3512C, G3512E, G3516C, G3520C, AND G3520E ENGINES

MODELS INVOLVED - CERTAIN G3512C, G3512E, G3516C, G3520C, AND G3520E ENGINES

Dear Cat Product Owner:

The Rotocoil used on the valve springs may need to be replaced on the products listed below. The existing Rotocoil can lose the ability to rotate resulting in premature wear and failure. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 16May2014 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 16May2014 Service Letter

Rework Procedure

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Before completing the attached Rework Procedure; Please review the safety actions in the Operation and Maintenance Manual for the engine.

This picture represents a good (316-5978)(Rotocoil AS) without tabs showing.

Image1.1.1

This picture represents a rotocoil with tabs that will need to be replaced with (316-5978)(Rotocoil AS).

Image1.2.1

If rework tool is needed, fabricate tool in attached drawings and use the following rework procedure.

Image1.3.1

Image1.3.2

Image1.3.3

Image1.3.4

1. Bring cylinder to Top Dead Center

2. Remove transformer and wiring

3. Remove rocker cover

4. Remove rocker arms and shafts

5. Remove rocker box and bridges

6. Remove pushrods

7. Remove spark plug

8. Place valve spring compression tool on top of all four valves centered over the spark plug hole.

9. Align positioning bolt (1), (2), with the lower rocker box bolt on the top left and the bridge bolt on the bottom right. Tighten these bolts unit lightly seated. (Image 1.4.1)

Image1.4.1

10. Ensure that the center of the tool is aligned above the spark plug hole and carefully thread main jackscrew into place (3). (Image 1.5.2)

Image1.5.2

11. With jackscrew (3) tightened into spark plug hole. While holding jackscrew with 9/16 wrench (4), Tighten 1 1/8 nut (5) to compress the valve springs. (Image 1.6.1)Be cautious not to damage spark plug threads. Stop tightening once the top of the jackscrew in 10cm from the top of the plate.(Image 1.6.2)

Image1.6.1

Image1.6.2

12. Continue compressing valve springs until stand offs on tool are seated against head (6). DO NOT TIGHTEN ANY FURTHER; SPARK PLUG ADAPTER DAMAGE COULD RESULT. (Image 1.7.1)

Image1.7.1

13. Valve stems and keepers should now be accessible. Use magnet to remove 2 keepers from each valve stem. (7) (Image 1.8.1)

Image1.8.1

14. Once all keepers are removed, start to loosen 1 1/8 nut, (5) while holding jackscrew with 9/16 wrench (4), to relieve the pressure from the springs.

15. Nut (5) should be completely loose then the positioning bolts (1 and 2) can be removed and plate can be taken off.

16. Remove old rotators and install new rotators.

17. Repeat steps 7-12 to reinstall the keepers.

18. Once keepers are in place, start to loosen 1 1/8 nut, (5) while holding jackscrew with 9/16 wrench (4), to relieve the pressure from the springs. Ensure keepers stay in groove while loosening.

19. Nut (5) should be completely loose then the positioning bolts (1 and 2) can be removed and plate can be removed.

20. Reinstall spark plug with new gasket 9Y-6792

21. Reinstall rocker box with new gasket 296-5820

22. Reinstall pushrods

23. Reinstall valve bridges and adjust

24. Reinstall rocker arms and adjust

25. Mount rocker box

26. Reinstall transformer and wiring

27. Move next cylinder to TDC and start procedure over again until all 332-7386
rotators have been replaced with 316-5978 rotators.