PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST ROCKER ARM ON CERTAIN 24 MOTOR GRADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST ROCKER ARM ON CERTAIN 24 MOTOR GRADERS [UEBE0699]

BASIC ENGINE

VALVE MECHANISM GP

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST ROCKER ARM ON CERTAIN 24 MOTOR GRADERS

UEBE0699-01

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24Apr2020

(Revised 26Aug2020)

U-249

A-201

D-234

O-234

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST ROCKER ARM ON CERTAIN 24 MOTOR GRADERS
1102 1210		PS46674

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NOTE:

AVSpare’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 AVSpare.

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS46674" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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 AVSpare product analyst.

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NOTE:	This Revised Service Letter replaces the 24Apr2020 Service Letter. Changes have been made to the Parts Needed, and Service Claim Allowances.

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TERMINATION DATE

30Apr2022

PROBLEM

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The existing number 12 exhaust lobe and or rocker roller can spall on certain 24 Motor Graders. If the existing rocker arm or camshaft spalls at number 12 position it can affect engine performance.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
24-14	E9Z00201-00231

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*****Group 2*****
24-14	N9Z00102-00105, 201-218

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	1R0716	FILTER AS-LUBE (After Failure Only)
2	5E8771	SEAL-O-RING (After Failure Only)
2	5P8429	SEAL-O-RING (After Failure Only)
6	8S9191	BOLT (After Failure Only)
1	20R1895	CAMSHAFT (After Failure Only)
1	20R8517	ARM GP-V ROCKER
6	0315085	BOLT-LOCKING (After Failure Only)
1	1090076	SEAL-O-RING (After Failure Only)
2	1178801	SEAL-O-RING (After Failure Only)
1	2314708	SEAL-O-RING (After Failure Only)
3	2349508	BOLT-WASHER HEAD (Qty 1 Before Failure)
9	2351089	NUT-FLANGE (Qty 3 Before Failure)
9	3049553	STUD-6 PT HD (Qty 3 Before Failure)
1	OIL	ENGINE OIL per OMM (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% 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.
*****Group 2*****
2	1R0716	FILTER AS-LUBE (After Failure Only)
2	5E8771	SEAL-O-RING (After Failure Only)
2	5P8429	SEAL-O-RING (After Failure Only)
6	8S9191	BOLT (After Failure Only)
1	20R2931	CAMSHAFT (After Failure Only)
1	20R8517	ARM GP-V ROCKER
6	0315085	BOLT-LOCKING (After Failure Only)
1	1090076	SEAL-O-RING (After Failure Only)
2	1178801	SEAL-O-RING (After Failure Only)
1	2314708	SEAL-O-RING (After Failure Only)
3	2349508	BOLT-WASHER HEAD (Qty 1 Before Failure)
9	2351089	NUT-FLANGE (Qty 3 Before Failure)
9	3049553	STUD-6 PT HD (Qty 3 Before Failure)
1	OIL	ENGINE OIL per OMM (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 30% 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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Nominal wear is to be expected on valve train components during the course of engine life. Spalling and pitting may be present but do not necessarily indicate an eminent failure. A failure is considered when a machine is low on power due to the number 12 exhaust rocker arm / camshaft lobe wear is progressing towards a low power complaint or mechanical failure.

In all cases prior to failure, valve lash must be performed per OMM guidelines and a robust SOS program must be followed.

Before Failure:
Note: Only four bolts 3565212 are required for one rocker shaft removal, per engine.
Step 1: Gain access to right hand side Valve Mechanism Covers, reference the engines Disassembly and Assembly Manual for instructions in removing necessary components.

Step 2: Remove right hand side valve mechanism covers for cylinders 10 and 12. Refer to Dissemble and Assembly, "Valve Mechanism Cover - Remove and Install".

Step 3: Remove right hand side rocker arm assembly at cylinders 10 and 12. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Remove".

Step 4: Remove the number 12 exhaust valve rocker from assembly. Refer to Disassembly and Assembly, "Rocker Arm - Disassemble" and "Rocker Arm - Assemble".

Step 5: Install Rocker Arm Assembly. Refer Disassembly and Assembly, "Rocker Arm and Shaft - Install".

Step 6: Adjust the valve lash for the inlet valves and the exhaust valves. Refer to Testing and Adjusting, "Engine Valve Lash - Inspect".

Step 7: Install the valve mechanism cover. Refer to Dissemble and Assembly, "Valve Mechanism Cover - Remove and Install".

After Failure:
Before submission of an After Failure claim to this service letter, please attach records of valve lash and SOS history.

Reference appropriate Machine manual to identify proper procedure for removing machine components, as the camshaft may be removed from front or rear of engine.

Access to following tooling is required to remove camshaft
177-8001 Pilot Sleeve
249-2936 Adapter
274-7932 Guide ( Front Removal)
274-7933 Guide ( Rear Removal)

Step 1: Gain access to right hand side Camshaft Covers and Valve Mechanism Covers, reference the engines Disassembly and Assembly Manual for instructions in removing necessary components.

Step 2: Remove right hand side valve mechanism covers. Refer to Dissemble and Assembly, "Valve Mechanism Cover - Remove and Install".

Step 3: Remove right hand side rocker arm and shafts. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Remove".

Step 4: Remove right hand side camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".

Step 5: Install new camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".

Step 6: Replace rocker arm on rocker shaft. Refer to Disassembly and Assembly, "Rocker Arm - Disassemble" and "Rocker Arm - Assemble".

Step 7: Install rocker arm and shaft. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Install".

Step 8: Install valve mechanism covers. Refer to Dissemble and Assembly, "Valve Mechanism Cover - Remove and Install".

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-6000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-12000 hrs, 25-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 0.5-hour job for Group 1 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Before Failure: This is a 0.5 hour job if performed during routine valve lash adjustment. An additional 1 hour is allowed if performed independently of scheduled valve lash adjustment. For before failure repairs a qty of 3ea. 304-9553, 3 ea. 235-1089, and 1 ea. 234-9508 are allowed as only one actuator group assembly will need to be removed to install rocker arm. After Failure: An additional 37.5 hours are allowed for after failure.

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-6000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-12000 hrs, 25-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 0.5-hour job for Group 2 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Before Failure: This is a 0.5 hour job if performed during routine valve lash adjustment. An additional 1 hour is allowed if performed independently of scheduled valve lash adjustment. For before failure repairs a qty of 3ea. 304-9553, 3 ea. 235-1089, and 1 ea. 234-9508 are allowed as only one actuator group assembly will need to be removed to install rocker arm. After Failure: An additional 37.5 hours are allowed for after failure.