COVER AS-BASE 2180397 - Caterpillar

SEBE8226-02 December 5, 2002
(Revised June 2003)
U-315
A-218
AU-231
S-230
H-229
O-255
Afterfailure only PRODUCT SUPPORT PROGRAM FOR REPLACINGPISTONS ON CERTAIN 3606, 3608, 3612, AND 3616 INDUSTRIAL ENGINES
7755 PS50592
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 "PS50592" 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 December 5, 2002 (Revised April 2003) Service Letter. Changes havebeen made to the Service Claim Allowances.TERMINATION DATE
December 31, 2003PROBLEM
In certain circumstances, the 1214068, 1217555,and 4P0399 pistons may experience 3rd land cracking and may not reach thepublished life expectancy. Pistons need to be replaced on certain 3606,3608, 3612, and 3616 Industrial Engines.AFFECTED PRODUCT
Model Identification Number
3606 8RB563-571, 573-585,588-591, 593-610, 612-660, 662-690, 693-712, 714-735
3608 6MC478, 480-499, 501-513,515-595
3612 9RC176, 178, 185, 187,189-193, 195-217, 219-228, 230, 232-295
3616 1PD223-231, 236, 238,240-243, 246-252, 255, 262-266, 268-352PARTS NEEDED
The intention of this program is toreplace all pistons, in an engine, when there is a 3rd land failure. Itis not to cover engines that may be in the same application, but have nothad a failure.Parts Needed Per Cylinder
Qty Part Number Description
1 1110281 BOTTOM/OIL RING
1 1355149 TOP RING
1 1293581 2nd RING
1 1726772 PISTON AS.
1 1756597 3rd RING
Replacing partial sets of pistons dueto scheduling is acceptable.
Qty Part Number Description
8 8C5230 SEAL-O RING
2 8C9023 SEAL-O RING
2 6V4314 SEAL-O RING
1 1428615 BEARING
Additional Parts Per Cylinder Depending on Engine Configuration
Spacer Plate Configuration:
Qty Part Number Description
2 Piece Spacer PlateConfiguration
8 2N3350 SEAL-O RING
1 Piece Spacer PlateConfiguration
8 5P9890 SEAL-O RINGCombustion Gasket:Distillate with a 1793167 liner uses a 1422826combustion gasketDistillate with a 1161042 liner uses a 1457230combustion gasketACTION 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/FastFerry Parts Labor Parts Labor Parts Labor
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 63.4?hr job for the 3606.
This is a 83.7?hr job for the 3608.
This is a 122.2?hr job for the 3612.
This is a 162.0?hr job for the 3616.
PARTS DISPOSITION
Handle parts in accordance with the warranty bulletinon warranty parts handling, with actual pistons with 3rd land crack, beingsent to:R.A. Lofthouse3600 Customer ServicesLafayette Large Engine CenterPh. (765)448-5311
Attach. (1-Rework Procedure)Rework Procedure
Replace the existing 1214068, 1217555, and4P0399 pistons with the material provided in this program. The cylinderhead, rod, and piston assembly must be removed. The unit injector doesnot have to be removed, but proper blocking must be used when setting thehead down to keep from damaging the tip. Refer to the 3600 Disassemblyand Assembly manual (3606/08 SENR3600, 3612/16 SENR3594) for the correctprocedures to complete the repair. This after failure program is for 3rdland cracking only. The following illustrations are examples of 3rd landcracks. Typically there will be an increase in aluminum in the oil?s SOSresults and crankcase pressure will increase, prior to any operationalproblem. If either of these two signs occurs, inspection of the piston,either by boroscope or visual inspection at the bottom of the liner willgive indications of the land cracking. Illustration 1 Illustration 2 Illustration 3 Illustration 4