DRUM 5C9207 - Caterpillar

ACTION REQUIRED
Refer to the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-2000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
A new cylinder head gasket is available for certain 3024C engines fitted in machines.
SMCS Codes:
Valve mechanism cover remove / install 1107
Rocker shaft remove / install 1102,1208
Fuel injection lines remove / install 1252
Fuel injection nozzles remove / install 1254
Engine oil lines remove / install 1307
Note: Care must be taken to ensure that fluids are contained during this rework procedure. If fluids are not to be re-used disposal must be in line with local regulations and mandates.
Refer to Appropriate Service Manual as necessary.
Rework procedure:
1. Clean the engine down before commencing work ? see "Engine ? Clean" in the OMM.
2. Remove the valve mechanism cover ? D&A, valve mechanism cover remove.
3. Remove the rocker shaft and pushrods ? D&A, rocker shaft and pushrod remove.
4. Remove the fuel injection lines ? D&A, fuel injection lines remove.
5. Remove the fuel injection nozzles ? D&A, fuel injection nozzles remove.
6. Remove the oil line ? D&A, engine oil line remove.
7. Gradually loosen the cylinder head bolts (1) in the reverse order to that shown in the image below. This will prevent distortion of the cylinder head (2).
Image1.1.1
Image1.1.2
8. Attach a suitable lifting device to the cylinder head (2) and carefully lift it from the cylinder block (3).
9. Take care to ensure that the old gasket material is thoroughly cleaned from both cylinder head & block surfaces, without scratching the surface finish of either part.
Refer to SMCS 1100 for min & max distortion specifications. Refer to SMCS 1100-040 for flatness specifications.
Image1.2.1
10. Place the new cylinder head gasket on the cylinder block top deck (3) ? ensure it is the correct orientation and located on the two dowels (6).
11. Do not use any gasket sealant or compound on the cylinder head gasket.
Image1.3.1
12. Use a suitable lifting device to lift the cylinder head back over the cylinder block.
13. Place cylinder head (2) onto the cylinder block (3), ensure that the cylinder head is positioned on the two dowels (6) and verify that the head gasket is positioned correctly.
14. Lightly lubricate the cylinder head bolts (1) with clean engine oil.
15. Install the cylinder head bolts (1) and start the threads by hand.
16. Gradually tighten the cylinder head bolts in the numerical sequence shown to a final torque of 101 Nm (74 lb/ft).
17. Install the oil line.
18. Install the injection nozzles.
19. Install the fuel injection lines.
20. Install the rocker shaft and pushrods.
21. Over check the valve clearances and adjust as necessary.
22. Install the valve mechanism cover ? D&A, valve mechanism cover.
23. Refill the cooling system.
24. Prime the fuel system.
25. Start and run the engine.
26. Run the engine until normal operating temperature is reached and check for signs of oil or coolant leakage - rectify as necessary.