40022 17 Mercury WASHER, CARBURETOR STUD

May 17, 2001
U-114
A-75
AU-67
S-50
O-87
beforeor
after failure PRODUCT SUPPORT PROGRAMFOR CHECKING THE HIGH COMPRESSION RATIO (HCR) EXHAUST VALVE RECESSION ONCERTAIN G3600 ENGINES
1100 PS40487
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS40487"as the Part number and "7755" as the Group Number. If administered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If administered after failure, use "96" as theWarranty Claim Description Code 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.TERMINATION DATE
May 31, 2006PROBLEM
The G3600 High Compression Ratio (HCR) application,10.5:1 and 11:1, are configured with an exhaust valve that is experiencingan unacceptable recession rate. The purpose of this program is to replaceor rebuild those cylinder heads, which do not meet the expected life of16,000 hours. This will resolve the exhaust valve recession problems byreplacing the nimonic valve with a stellite valve.AFFECTED PRODUCT
Model Identification NumberG3612 1YG1-203G3616 4CG1-190PARTS NEEDED (for each cylinder replaced)
The following gasket kit is needed for each cylinderhead replacement or rebuild effort:1 ? 1711496 GASKET KIT In addition to the above gasketkit, miscellaneous bolts, gaskets, washers might be needed. The total costof misc. parts is not to exceed $150US for each cylinder head replacementor rebuild activity.The following parts are required whenreplacing a cylinder head:1 ? 0R9264 HEAD GP-CYLThe following parts are to be used to rebuildthe 1713395 or 0R9752 cylinder head assemblies:2 ? 1851103 VALVE ? EXHAUST2 ? 1713993 INSERT ? EXHAUST VALVE SEATACTION REQUIRED
This program is intended to replace the 1611205or 0R9478 with the 0R9264 remanufactured cylinder head group. Replacementof cylinder heads will occur on engines with a serial number rangeof 1YG1-176 for the G3612, and 4CG1-151 for the G3616.Engines currently using the 1713995 or 0R9752Cylinder Head assemblies should be rebuilt using the hardware defined inthe parts needed section of this program. The serial number ranges forthese engines is 1YG178-203 for the G3612 and 4CG152-190 for the G3616.Cylinder head assemblies should be replacedor rebuilt in the event that the exhaust valve recession exceeds a maximumof 3mm of total recession, or if the recession rate exceeds a 2mm changeover a 1000 hours period.Refer to standard cylinder head replacementand rebuild procedures to complete the required rework. When rebuilding a cylinder head, usedry-ice to freeze the valve seat. This will make the installation of thevalve seat into the cylinder head easier.SERVICE CLAIM ALLOWANCES
Component smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-16000 90 % 14* 10 % 0 0 0
* Note:An additional 4 hours of labor will be allowed for rebuiling a cylinder head. The maximum number of cylinder headreplacements or rebuilds, or any combination of replacements and rebuilds,for each engine qualifying for this program will be 12 for the G3612, and16 for the G3616. Cylinders which have already been updated with the latesthardfaced exhaust valve configuration are not intended to be a part ofthis program.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.