LOCKNUT 3K2889 - Caterpillar

REBE3850-00
16Jul2008
U-375
A-303
O-340
After Failure Only
PRODUCT SUPPORT PROGRAM FOR REPLACING THE CYLINDER HEADS ON G3520C LANDFILL ENGINES
1105 1100 1101 1052 1053 PS51521
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 Numberand "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
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.
TERMINATION DATE
31Jul2010
PROBLEM
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
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
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
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.
Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-8000 hrs 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
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