PUMP GP-METERING 2Y6399 - Caterpillar

SEBE7042-04 October 18, 1999
(Revised January 2003)
U-290
A-225
AU-184
S-157
H-114
O-247
TM-5
After failure only
PRODUCT SUPPORT PROGRAM FOR REWORKINGTHE INLET VALVES THAT MAY FAIL PREMATURELY ON CERTAIN 3116 MARINE ENGINES
1105 PS5711
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS5711" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description 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 October 18, 1999 (Revised November 2001) Service Letter. Changes havebeen made to the Termination Date.TERMINATION DATE
October 31, 2003PROBLEM
The inlet valve may fail prematurely on certain3116 Marine Engines. This program is not intended to coverengine replacements. If a valve failure causes an engine replacement, theengine should be replaced under normal warranty or goodwill if needed.AFFECTED PRODUCT
Model IdentificationNumber
3116 4KG6600-84001SK2000-2248
The serial number of the sister enginein the same boat may also be affected. If the PIN on the sister engineis below 4KG8400 or 1SK2248, perform this rework on that engine beforefailure.PARTS NEEDED
Quantity Part Number Description
1 7C1159 Gasket
1 7C7613 Gasket? Outlet
3 3D2824 Seal? O-Ring
1 7E0844 Seal
1 4F7391 Seal? O-Ring
1 6F6673 Seal? O-Ring
1 3J1907 Seal? O-Ring
1 9M4849 Seal? O-Ring
1 4P7704 Gasket? Turbocharger
1 1S7057 Gasket
2 8T0280 Seal? O-Ring
1 6V8397 Seal? O-Ring
1 2W7212 Gasket? Regulator
1 7W2398 Gasket
1 1077832 Gasket
3 1136200 Gasket
1 1136250 Gasket
6 1148718 Seal? O-Ring
1 1169924 FilterAssembly ? Oil
1 1192940 Gasket
12 1193036 Seal? Valve Stem
6 1577125 Valve? Inlet
6 1577126 Valve? ExhaustACTION REQUIRED
See the attached Rework procedure.SERVICE CLAIM ALLOWANCES
Product smu/age whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts (D/N) Labor Hrs (Cost) Parts Labor Hrs Parts (C/L) Labor Hrs (Sell)
Unlimited 100% 36.6 0 0 0 0
This is a 36.6-hour job.
The age and hours for this programare unlimited. All labor at sell rate and parts at customer list are reimbursed100% by Caterpillar.
Labor Hour Breakdown (In Boat Repair)
SMCS code Hours Description
1100-010 3.0 R & I Hatches
1100-001 24.0 R & I Cylinder Head*
1100-010 2.6 Repair Cylinder Head
1100-010 1 (each engine) Paint Parts
1100-010 1 (each engine) Clean Boat
1100-010 1 (each engine) Test After Repair
1100-010 4.0 Travel Time* 9 hours to R & I Cylinder Head in shopPARTS DISPOSITION
In North America, as a condition ofpayment for this Product Support Program, the replaced inlet valves (withthe valves clearly numbered as to which cylinder and engine they came from)must be returned to the following address:
CATERPILLAR INC.
8201 N. UNIVERSITY-DOCK 22PEORIA, IL 61615ATTENTION: SETH STUDNICKA Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.Attach. (1-Rework Procedure)
REWORK PROCEDURE
1. Drain oil and coolant.2. Inspect for loose rivet at governor linkto rack bar connection as per instructions in TIB dated April 22, 1998titled "Loose Rivet in Rack Control Assembly".3. Remove rack control assembly and fuel injectorsfrom cylinder head.4. Remove the cylinder head, aftercooler, turbo,and exhaust manifold per the Service Manual. The aftercooler does not haveto be disconnected from the intake manifold for removal.5. Remove the 1136180 Intake Valves from thecylinder head.6. Remove the 1014541 Exhaust Valves from thecylinder head.7. Dress each exhaust valve seat. Maintainrecession of the valve head 1.51 - 2.22 mm (0.059 - 0.087 in) below thefire deck surface of the cylinder head.8. Dress each intake valve seat. Maintain recessionof the valve head 1.13 - 2.05 mm (0.044 - 0.081 in) below the fire decksurface of the cylinder head.9. Ream fuel injector sleeves to get a goodseat for the injector