PLUG AS 3960405 - Caterpillar

SEBE9139-01 April 20, 2005
(Revised June 2005)
U-115
A-85
D-96
O-101
Priority PRODUCT IMPROVEMENT PROGRAM FOR INSPECTINGTHE CYLINDER HEAD VALVE ROTATOR ON CERTAIN G3516 AND G3520 GAS ENGINES
1121 PI30777
This Program must be administered assoon as possible. When reporting the repair, use "PI30777" as the Partnumber and "7751" as the Group Number, "56" as the Warranty Claim DescriptionCode and "T" as the SIMS Description Code. Exception: If the repair isdone after failure, use "PI30777" as the Part Number, "7751" as the GroupNumber, "96" as the Warranty Claim Description Code, and "Z" as the SIMSDescription Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe April 20, 2005 Service Letter. Changes have been made to the AffectedProduct.
COMPLETION DATE
TERMINATION DATE
October 31, 2005 April 30, 2006PROBLEM
The cylinder head valve rotator needs to be inspectedon certain G3520 and G3516 Generators Sets. Due to a design tolerance stackup problem the cylinder head valve rotator could interfere with the valvebridge assembly. This could cause the bridge to contact the valve rotator,damaging both and leading to possible valve failure. The engines need tobe inspected, and adjusted if necessary.A program PI30680 was issued June 2004 to completethe same inspection and repair but this has been determined not reliabledue to parts wear predictions were under estimated. The same inspectionand repair method is still being requested with additional material beingremoved.AFFECTED PRODUCT
****Group 1****
Model Identification Number
G3516 TJB1-104TJC1-819
G3516E SLY1-107****Group 2****
Model Identification Number
G3520C CWW1-242B9P1-214MAD1-201CWY1-216HEA1-102HEB1-104HAT1-205PARTS NEEDED
No parts are needed for this rework.ACTION REQUIRED
See the attached Rework Procedure.OWNER NOTIFICATION
U.S. and Canadian owners will receive the attachedOwner Notification.SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
100% 3.0 0 0 0 0
This is a 3-hour job to inspect allcylinders. If rework is needed, an additional one hour per cylinderwill be allowed. The number of cylinders that need to be reworked willvary. U.S. and Canadian Dealers Only - Eligibledealers may enter a Type 2 SIMS ReportPARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.MAKE EVERY EFFORT TO COMPLETE THIS PROGRAMAS SOON AS POSSIBLE.Attach. (1-Owner Notification)
(2-Rework Procedure)COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999PRIORITY - PRODUCT IMPROVEMENT PROGRAM FORINSPECTING THE CYLINDER HEAD VALVE ROTATORMODELS INVOLVED - G3516 AND G3520 GAS ENGINESDear Caterpillar Product Owner:The cylinder head valve rotator needs to beinspected and potentially reworked on the products listed below. You willnot be charged for the service performed.Contact your local Caterpillar dealer immediatelyto schedule this service. The dealer will advise you of the time requiredto complete this service. Please refer the dealer to their Service Letterdated April 20, 2005 when scheduling this service.We regret the inconvenience this may causeyou, but urge you to have this service performed as soon as possible toprevent unscheduled downtime.Caterpillar Inc.
Identification #(s)Attached to April 20, 2005 Service LetterRework ProcedureInspect and repair if necessary.
Using a .080-inch (or 2.0 mm) gage wire, placebetween the rotator and bridge. If the gage wire passes through the spacethe clearance is ok.
If the gage wire will not pass through the