BEARING-SLEEVE 2036090 - Caterpillar

SEBE8425-01 June 28, 2003
(Revised November 2003)
U-173
A-121
D-128
O-147
TM-4
Afterfailure only PRODUCT SUPPORT PROGRAM FOR REPLACING PISTONS ON CERTAIN 3606, 3608, 3612,AND 3616 MARINE ENGINES
7755 PS50670
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 "PS50670" 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 June 28, 2003 Service Letter. Changes have been made to the AffectedProduct and Parts Needed.TERMINATION DATE
June 30, 2005PROBLEM
Pistons on certain 3606, 3608, 3612, and 3616Marine Engines need to be replaced. In certain circumstances, the 1726772pistons may experience nut loosening or abnormal outer abutment wear. The2183589 piston may experience nut loosening as well.AFFECTED PRODUCT
Model Identification Number
*** Group 1 ***
3606 8RB870-Up
3608 6MC663-Up
3612 9RC384-Up
3616 1PD393-Up
*** Group 2 ***
3606 8RB736-869
3608 6MC596-662
3612 9RC296-383
3616 1PD353-392PARTS NEEDED
The intention of this program is toreplace only failed pistons, in an engine, when there is a 1726772 nutfailure or wear issue and to replace all pistons, when there is a 2183589nut failure. It is not to cover engines that may be in the same application,but have not had a failure. The 2183589 is a heavier weight pistonand cannot be mixed with any other piston part number.
Qty
Part Number Description
*** Group 1 ***
1 9X2838 GASKET KIT
1 1110281 BOTTOM/OIL RING
1 1187536 SEAL-O RING
1 1371574 TOP RING
1 1371575 2ND RING
1 1976700 PISTON AS.
*** Group 2 ***
1 9X2838 GASKET KIT
1 1110281 BOTTOM/OIL RING
1 1187536 SEAL-O RING
1 1293581 2ND RING
1 1355149 TOP RING
1 1756597 3RD RING
1 2414949 PISTON AS. The 1976700 piston will be availableOct 2003 through the Morton Parts system and is replacing both the 2183589and 2414949 piston, except in Defense and Federal Products units, whichcontinue to utilize the 2414949 piston as identified in group 2. The 1976700is a direct replacement for the 2414949, even though it is a three ringdesign. They are the same weight.ACTION REQUIRED
See the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Piston hours Caterpillar Dealer Suggested Customer Suggested
Distillate Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-10000 100% 100% 0 0 0 0
10001-20000 75% 75% 0 0 25% 25%
20001-30000 50% 50% 0 0 50% 50%
30001-Up 0% 0% 0 0 100% 100%
HFO Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-5000 100% 100% 0 0 0 0%
5001-10000 75% 75% 0 0 25% 25%
10001-15000 50% 50% 0 0 50% 50%
15001-Up 0% 0% 0 0 100% 100%
This is a 64?hr job for the 3606.
This is a 85?hr job for the 3608.
This is a 128?hr job for the 3612.
This is a 170?hr job for the 3616.PARTS DISPOSITION
Return pistons with nut failures to:R.A. Lofthouse3600 Customer ServicesLafayette Large Engine CenterPh. (765)448-5311Attach. (1-Rework Procedure)Rework Procedure
Replace the existing 2414949 and 2183589 pistonswith the material provided in this program. The cylinder head, rod, andpiston assembly must be removed. The unit injector does not have to beremoved, but proper blocking must be used when setting the head down tokeep from damaging the tip. Refer to the 3600 Disassembly and Assemblymanual (3606/08 SENR3600, 3612/16 SENR 3594) for the correct proceduresto complete the repair. This after failure program is for nutloosening and abnormal wear only. The 2414949 wear at the outer abutmentis to be measured, in the cold condition, and the piston is reuseable ifthe gap is measured 0.25mm or less. If the gap is larger then this do notreuse. Illustration 1 Illustration 2 (skirt?s outer abutment, when thegap was measured above 0.25mm.)
The