LINES GP-AIR 8N4398 - Caterpillar

been peformed due to detonation on those particular cylinders, all remaining cylinder packs should be replaced.
Use a boroscope to verify cylinder liner polishing is occuring prior to replacing the cylinder pack. A significant loss of crosshatch near top ring turn-around, wear step, and/or shiny polished appearance indicate heavy liner polishing. Refer to Image 1 for an example of heavy liner polishing.
Monitor and trend oil consumption, blowby, and cylinder compression per guidelines in the Operation and Maintenance Manual (SEBU7681). The trends developed for these three conditions are used in determining when the engine has reached an in-frame overhaul interval. If the guidelines in the Operation and Maintenance Manual are met, all cylinder packs will need replaced.
If multiple cylinder packs are replaced the parts quantities should be adjusted accordingly.
Fully read and understand the rework procedure prior to applying this program or ordering replacement parts.
Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-8000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
8001-15000 hrs,
49-96 mo 75.0% 75.0% 0.0% 0.0% 25.0% 25.0%
15001-30000 hrs,
97-144 mo 50.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 10.0-hour job
An additional 8 hours labor will be allowed for each additional cylinder pack replaced.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Refer to appropriate service manual as necessary.
If this is the 3rd cylinder that has been replaced due to heavy liner polishing, then all remaining cylinder liners should be replaced following this rework procedure.
If oil consumption, blowby, and/or cylinder compression has exceeded the guidelines in the Operation and Maintenance Manual (SEBU7681) for In-frame Overhaul, then all cylinder liners should be replaced. Document the trends for these three parameters.
Procedure:
1) Verify and document single cylinder detonation of a particular cylinder by capturing logged events from Caterpillar Electronic Technician.
2) Perform all appropriate detonation troubleshooting for that cylinder. Refer to Troubleshooting Guide, "Detonation Occurrence". Verify that the ignition system, detonation system, engine wiring, and valve lash are not the cause of the detonation alarms. It is also important to ensure that the engine is applied properly, for example rated for fuel, altitude, and ambient conditions. Use the appropriate Troubleshooting Manual for this step.
3) Use a boroscope to verify cylinder liner polishing is occurring prior to replacing the cylinder pack.
Note: Follow Disassembly and Assembly Manual for the appropriate removal and installation procedures. Cleanliness is an important factor. The exterior components should be thoroughly cleaned before beginning the disassembly procedure. This will help prevent dirt from entering the internal mechanism. Precision components can be damaged by contaminants and/or by dirt. Keep components covered and protected at all times.
4) Remove the single cylinder pack experiencing detonation.
5) Engines can have a mix of old and new piston part numbers, the new pistons (262-2061) and the old pistons can be in the same engine. Dimensions and weights are the same. If a new piston is to be installed in a cylinder where an old piston was removed, the piston oil jet for that cylinder will need to be replaced with the 260-0135