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i02668462
Engine:
G3516C (S/N: GSB1-UP; TJB1-UP; TJC1-UP; TJD1-UP; GZZ1-UP; RWA1-UP;
GHG1-UP; DKR1-UP)
G3516E (S/N: SLY1-UP)
G3520C (S/N: GZJ1-UP)
G3520E (S/N: GZH1-UP)
Generator Set:
G3516E (S/N: GAS1-UP; GHP1-UP)
G3520C (S/N: MAD1-UP; GZK1-UP; GZL1-UP; GZM1-UP; GZN1-UP; B9P1-UP;
HAT1-UP; CWW1-UP; CWY1-UP; GDB1-UP; GHC1-UP; GHE1-UP; JBX1-UP;
JBZ1-UP)
G3520E (S/N: GZG1-UP; HAL1-UP; SXY1-UP; GHM1-UP; GHR1-UP)
Introduction
The problem that is identified below does not have a permanent solution at this time. Until a
permanent solution is known, use the solution that is identified below.
Problem
Failures of the cylinder head valves on some G3500C and G3500E Generator Set Engines have
been reported.
The aggressive profiles on the camshaft lobes for these engines make the valve lash clearance
adjustments and the valve bridge adjustments critical.
If the valve lash increases beyond the specification, the valve will seat while the valve lifter is
traversing the aggressive profile of the camshaft lobe. On this part of the camshaft lobe, the valve
is traveling at a velocity that is beyond the specification for seating the valve. The increased
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velocity during seating causes an increased load on the valve stem. The increased load on the
valve stem may lead to failure of the valve. Any increase in valve lash that is beyond the
specification may cause failure of the valve.
Solution
The correct valve lash clearance adjustments and valve bridge adjustments is critical. The
recommendation for adjustment of the valve lash has been updated for all G3500C and G3500E
engines.
The valve recession must also be checked during adjustment of the valve lash and the valve
bridges. Record these measurements. This will provide a history of valve recession. History of
valve recession is used to indicate wear of the valve and of the valve seat.
The crankshaft position for valve lash settings must begin with the number one piston at Top
Center (TC). The flywheel must be pinned prior to the start of the valve adjustment. Refer to
Systems Operation/Testing and Adjusting, RENR5978, "Finding the Top Center Position for the
No. 1 Piston" for information.
Check the clearance between the valve bridge and the valve rotator for each valve. Also, perform a
visual inspection of the clearance between the rotators and the valve cover base. Refer to
Technical Information Bulletin, TIBU4572-01, "Improper Valve Rotator Clearance on G3500
Series Engines" for the procedure. Correct any problems that are found.
Preliminary adjustments must be made when a cylinder head has been replaced. Perform this
procedure regardless of the reason for the replacement of the cylinder head.
1. Complete the valve lash clearance adjustments and the valve bridge adjustments prior to
starting the engine.
Make these adjustments for each cylinder head that has been replaced.
2. Start the engine and operate the engine at full load for one hour.
3. After one hour of operation, adjust the valve lash and the valve bridges again.
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Perform valve lash clearance adjustments and the valve bridge adjustments for every 1000 service
hours. This is considered to be normal engine maintenance.
Refer to Operations and Maintenance Manual, SEBU7681 for information that is related to the
maintenance intervals for your engine.
Check the valve recession at every 1000 hour service interval. This will give an adequate number
of data points for tracking the valve recession. This interval for the measurements replaces the
schedule that is published in Operations and Maintenance Manual, SEBU7681 until further notice.
The measurements for the valve recession must be recorded and the valve recession must be
plotted at each valve adjustment in order to establish a trend for the valve wear.
Check the measurement data for a difference in the valve recession that is greater than 1 mm
(0.039 inch) for the valves that share a valve bridge. If this measurement is exceeded for two
successive measurements, replacement of the cylinder head is necessary.
For example, one intake valve is measured and a recession of 1.35 mm (0.053 inch) is recorded. If
the other intake valve that shares the valve bridge is measured and a recession of 0.35 mm (0.014
inch) is recorded, then the cylinder head must be replaced.
Also, if the recession that is measured for any valve exceeds 2.3 mm (0.091 inch) the cylinder
head must be replaced. Refer to Operation and Maintenance Manual, SEBU7681.
If there is a question about replacement of a cylinder head, ask your technical communicator to
contact the Caterpillar Dealer Solution Network (DSN) for assistance in determining whether the
cylinder head should be replaced.
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• Failure mode
• Engine hours
• Recent service information (valve lash clearance adjustment and valve bridge adjustment)
• Dealer's preference for change interval (service hour interval or oil analysis program)
Cylinder head - Return all pieces of the valve that can be retrieved. Do not disassemble the
cylinder head.
Valve bridges - Leave the adjustment screw intact. Mark the bridges for the intake valves and the
exhaust valves.
Pushrods - Mark the pushrods for the intake valves and the exhaust valves.
Lifters - Mark the lifters for the intake valves and the exhaust valves.
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Table 1
Return Information for Failed Components
Engine serial number
Hours on the engine
Hours on the parts
Most recent valve lash adjustment
History of the valve recession (intake valve and
exhaust valve)
Records of the engine's oil changes (oil type and
interval)
Based on S·O·S Oil Analysis or on
Dealer's preference for oil change interval
Service Hours
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