PANEL GP-RH 6G2890 - Caterpillar

Caterpillar: Confidential Yellow
This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use 'PS50078' as the Part number and '7755' as the Group Number. Use '96' as the Warranty Claim Description Code and use 'Z' as the SIMS Description Code.
Termination Date
June 30, 2002Problem
Engines may need to be repaired due to cracked main bearing caps on certain 3508, 3512 and 3516 Engines used in off-highway trucks, track type tractors, hydraulic excavators and wheel loaders or generator set, industrial, marine, locomotive, marine auxiliary and vehicular applications. A process was omitted during the manufacturing of the cylinder block main caps on certain 3500 Engines. Because of the omitted process, the main cap may crack. This crack may be detected during a regular maintenance interval or in the worst case, the crack may not be detected until the engine fails.
Affected Product
Section 1 - Machine Engines
Group 1
776B (6JC1-UP)
777B (4YC1-UP)
776C (2TK1-UP)
777C (4XJ1-UP)
776D (5ER1-UP)
777D (3PR1-UP)
776D (AFS1-UP)
777D (AGC1-UP)
D11N (74Z1-UP, 4HK1-UP)
D11R (9TR1-UP, 9XR1-UP, 8ZR1-UP)
D11R (AAF1-UP, 7PZ1-UP)
992G (7HR1-UP, ADZ1-UP)
854G (1JW1-UP)
5130 (7TJ1-UP, 5ZL1-UP)
5130B (4CS1-UP)
Group 2
785C (1HW1-UP, APX1-UP)
785B (6HK1-UP)
777D HAA (2YW1-UP)
Group 3
789 (9ZC1-UP)
789B (7EK1-UP)
789C (2BW1-UP)
793 (3SJ1-UP)
793B (1HL1-UP)
793C (4AR1-UP4GZ1-UP, ATY1-UP)
785C HAA (5AZ1-UP)
5230 (7LL1-UP)
994 (9YF1-UP)
994D (3TZ1-UP)
Section 2 - Commercial Engines
Group 1
3508 (23Z1-UP, 5PW1-UP, 70Z1-UP, 3LS1-UP, 5XM1-UP, 97Y1-UP)
3508B (2HW1-UP, 4GM1-UP, 6PN1-UP, 5KW1-UP, 68Z1-UP, 95Y1-UP, 69Z1-UP, 96Y1-UP, 3HM1-UP, 9WN1-UP, 3PS1-UP, 5PS1-UP, 1TW1-UP, 2BM1-UP, 7SM1-UP, 3DM1-UP, 3DW1-UP)
Group 2
3512 (2WK1-UP, 1LM1-UP, 49Y1-UP, 65Z1-UP, 24Z1-UP, 67Z1-UP, 6WW1-UP, 3MS1-UP, 6PM1-UP, 50Y1-UP, 66Z1-UP, 3RS1-UP, 51Y1-UP, BAG1-UP, 3WS1-UP)
3512B (8EM1-UP, 2GW1-UP, 4TN1-UP, 7HM1-UP, 2EZ1-UP, 4AW1-UP, 6WN1-UP, 8RM1-UP, 6GW1-UP, 5AW1-UP, 3ZW1-UP, 8DF1-UP)
3512B M/ (1PW1-UP)
Group 3
3516 (3XS1-UP, 25Z1-UP, 5SJ1-UP, 73Z1-UP, 8TW1-UP, 27Z1-UP, 71Z1-UP, 29Z1-UP, 72Z1-UP, 3SS1-UP)
3516B (3CW1-UP, 8CN1-UP, 8KN1-UP, 4BW1-UP, 3NS1-UP, 7KM1-UP, 1NW1-UP, 6HN1-UP, 7RN1-UP, 8NW1-UP, 2JW1-UP, 9WF1-UP, 2FW1-UP, 9AN1-UP)
DV098 (3JS1-UP)
DV099 (2TS1-UP)
E110B (9HF1-UP)
Failure Identification:
The failure mode of a broken main cap can occur at any SMU. To identify a main bearing cap crack that qualifies for this program, the cap must have a crack similar to the cap in Illustration 1 below. The crack MUST initiate from the either fillet radius of the cap. The cap may only be cracked or may be broken in two pieces.
Main caps with cracks in any other position DO NOT qualify for the program.
Illustration 1Parts Needed
Group 1
1 - 1524994 Crankshaft Assembly (for 3508 only)-Or-1 - 1527625 Crankshaft Assembly (for 3508B)1 - 1153503 Block Group-Cylinder (for 3508 and 3508B)Group 2
1 - 1286786 Crankshaft Assembly (for 3512 and 3512B)1 - 1155154 Block Group-Cylinder (for 3512 and 3512B)Group 3
1 - 1286788 Crankshaft Assembly (for 3516 and 3516B)1 - 1155160 Block Group-Cylinder (for 3516 and 3516B)Action Required
See that attached Rework Procedure.
Service Claim Allowances
Option I: The dealer repairs failed engine.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
Section 1 - Guidelines for Reusable Parts and Special Instructions:
The following is a list of Guidelines for Reusable Parts and Special Instructions for 3500 Cylinder Blocks and 3500 Crankshafts. These publications are listed as a reference in the event that they are needed during the repairs.
3500 Cylinder Blocks
Guidelines for Reusable