UNION 4D2560 - Caterpillar

MAY 2009
INFORMATION RELEASE MEMO
Reman
PELJ1045 ?2009 Caterpillar
REMAN 3500 ENGINE
CORE ACCEPTANCE CRITERIA REVISION
AND OTHER RECENT PRODUCT IMPROVEMENTS
Announcement
The Caterpillar Remanufactured Products Division is pleased to announce a change to the 3500 Engine Core Acceptance Criteria, SELD0164, which will make remanufactured product a more economical replacement option in many cases. Previously, if the core inspection identified a block was cracked or had been welded, the engine was given a damaged core refund. Effective immediately the core acceptance criteria will allow a full core refund with an add charge for the cracked/welded block. The add charge reflects the cost of replacing the block using the recently announced Reman UTN Bare Blocks (see following chart).
Engine Size New Block Reman Block (UTN)
3508 115-3503 (3500B), 100-3871 (3500A) 10R8416
3512 115-5154 (3500B), 100-3872 (3500A) 10R8415
3516 115-5160 (3500B), 100-3873 (3500A) 10R8417
This change will make rebuilding the engine with a Reman replacement block or replacing the engine with a Cat?Reman Engine more cost neutral and allow dealers greater repair option flexibility.
Other revisions to the core acceptance criteria include:
? Clarification on weld repairs
? Clarification on disassembly inspections
? Clarification on add charge assessments
Please review SELD0164-10 3500 Engines Core Acceptance Criteria to become familiar with these changes. All the latest core acceptance criteria guidelines can be found on the Reman Dealer Website at https://catreman.cat.com
Other Recent Improvements
Monotherm Piston Packs
A new remanufactured cylinder pack has been introduced for use in 3500 High Displacement Engines. The cylinder pack contains a one-piece forged steel piston (monotherm piston) and a drilled rod. Effective in May, this monotherm piston design will be used in all Reman 3500 High Displacement Engines.
The new pistons are a direct replacement for two-piece pistons which are currently used in 3500 High Displacement Engines. The new pistons have the same weight and balance as the previous pistons. The new pistons can be used in the same engine with the previous pistons. However, the 10R-9224 Cylinder Pack requires the 204-5447 Piston Cooling Jet As and the 193-3282 Retainer As (Piston Cooling Jet). When you are ordering and replacing cylinder packs in engines the cooling jet and the retainer must also be ordered and installed.
Note: Failure to install the correct piston cooling jet and the retainer will result in inadequate lubrication and cooling. This will cause piston seizure and catastrophic engine damage. Verify that the correct piston cooling jet is installed.
Table 1 illustrates the old part numbers and new part numbers. Illustration 1 shows the affected parts.
Table 1
Parts Ordering Information Two-Piece Monotherm
Cylinder Pack 10R-4029 10R-9224
Cooling Jet 162-3898 204-5447
Cooling Jet Retainer 121-3558 193-3282
Figure 1: (1) Piston, (2) Rod, (3) Cooling Jet
Stainless Steel Water Ferrule Inserts (large, small) Released as Serviced Part
Part Name Part Number Size (mm)
Plug/insert (small) 332-4533 20
Plug/insert (large) 332-4535 30
A typical repair process employed during an engine block rebuild is to insert stainless steel plugs where pitting has occurred in the water ferrule area. Stainless steel inserts used by Cat Reman to salvage 3500 engine