DRIVER 1760118 - Caterpillar

SEBE7667-01 July 5, 2001
(Revised August 2001)
U-159
A-108
AU-91
S-73
H-54
O-117
Afterfailure only PRODUCT SUPPORT PROGRAMFOR REPLACING 0R9264 REMANUFACTURED CYLINDER HEADS ON CERTAIN G3606, G3608,G3612, AND G3616 ENGINES
1100 PS50263
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 "PS50263" 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 July 5, 2001 Service Letter. Changes have been made to the Parts Needed.TERMINATION DATE
July 31, 2002PROBLEM
0R9264 Remanufactured cylinder heads may leakcoolant into the combustion chamber on certain G3606, G3608, G3612, andG3616 Engines. These leaks occur most frequently around the prechamberinsert that is pressed into the bottom of the cylinder head. The enginescan consume coolant and oil samples (SOS) may test positive for glycolor potassium.AFFECTED PRODUCT
Model Identification Number
G3606 3XF1-Up
G3608 4WF1-Up
G3612 1YG1-Up
G3616 4CG1-Up
The specific date code range for this ServiceLetter is from October 2000 ( UNNN ) through March 2001 ( NENU ).Determination of a suspect head must be validatedby the date code, which is located next to the "0R" part number. The "0R"part number can be located at the top left-hand corner of the head. Thedate code is formatted as ( MMYY )(for example: a head marked with a datecode of ( UUNN ) would indicate a part manufactured in November 2000. Headsnot displaying the following date codes are not eligible for this letter.
October 2000 ( UNNN ) January 2001 ( NUNU )
November 2000 ( UUNN ) February 2001 ( NMNU )
December 2000 ( UMNN ) March 2001 ( NENU )PARTS NEEDED
Quantity Part Number Description
1 0R9264 Cylinder Head (Useas Required)
1 171-1496 Gasket Kit (One PerCylinder Head)
In addition to the above gasket kit,miscellaneous bolts, gaskets, and washers might be needed. The total costof misc. parts is not to exceed $150 US for each cylinder head replacementor rebuild activity.ACTION REQUIRED
Procedural Checks in Determining PrechamberLeaksThe following are procedural checks to be usedin determining whether a prechamber coolant leak in a Gas 3600 engine ispresent. This procedure is necessary, due to the recent problem found onsome reman heads, where the leak is from the lower annular region of thehead PC interface. The steps and sequences might change depending uponthe site conditions, available tooling, time restraints, etc.
With the engine stabilized and running at normalload and speed record all cylinders exhaust port temps. Calculate the averagetemp and note any cylinders that seem to be out of the normal range. APC leak can cause the temp to go higher or lower.
Use the DDT in PC cal mode (Screen 50 - ALT2)to monitor the unfiltered burn times. Observe each cylinder for 1 minute.Investigate any cylinder that exhibits a burn time spike of 12 m/s or higher4 or more times in the 1minute. Keep in mind the misfire can be causedby many things other than a prechamber leak, i.e. spark plugs, check valves,cables, coils, spark plug