PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING PISTON RINGS ON CERTAIN C12, C18, AND 3406C MARINE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING PISTON RINGS ON CERTAIN C12, C18, AND 3406C MARINE ENGINES

Usage:

REBE6568-01

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28Oct2010

(Revised 18Jan2011)

U-439

A-359

D-382

O-382

TM-23

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING PISTON RINGS ON CERTAIN C12, C18, AND 3406C MARINE ENGINES
1225 1215		PI31816

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31816" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31816" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 28Oct2010 Service Letter. Changes have been made to the Parts Needed and Rework Procedure to specify inspection of the piston oil control ring.

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COMPLETION DATE	TERMINATION DATE
30Apr2011	31Oct2011

PROBLEM

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The piston rings need to be inspected and possibly replaced on certain C12, C18, and 3406C Marine engines. The existing piston rings may be installed incorrectly and can cause the engine to smoke excessively.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3406C	1SS02122-02124

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*****Group 2*****
C12	NFL01135-01148, 1150-1152, 1156-1167, 1177-1181, 1186, 1189

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*****Group 3*****
C12	NFL01133-01134, 1153-1155, 1169-1172, 1174-1176, 1183-1185, 1187

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*****Group 4*****
C18	JKX00380-00386, 388-390, 393-394

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*****Group 5*****
C18	GBM00277, 284, 287-294, 297, 299, 301, 306, 310 GES00244-00246, 248 T2P00942, 944-952, 954, 956-959, 962-967, 970, 976-977

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
6	2P2817	RING-PSTN-INTMED (As Required)
1	4C4200	PAINT-YELLOW (As Required)
1	6V4876	LUBRICANT (As Required)
1	6V9219	GASKET KIT
6	7N7078	RING-PSTN OIL (As Required)
6	1343761	RING-PSTN TOP (As Required)
1	1402576	PAINT-WHITE (As Required)
1	2232467	KIT-GASKET-CL
1	2233343	KIT-GASKET-ACL
1	2233345	KIT-GASKET-SCH
6	2835755	KIT-GASKET-SFI
6	2900017	BODY AS.-PISTON (As Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
1	1S4810	GASKET-OIL DRAIN
1	1S6595	GASKET
1	3K0360	SEAL-O-RING
1	4C4200	PAINT-YELLOW (As Required)
6	4G4972	SEAL-O-RING
1	5P5678	SEAL
1	5P7701	SEAL-O-RING (As Required)
1	5P8211	SEAL-O-RING
2	5S1105	SEAL-O-RING
2	6V3831	SEAL-O-RING
1	6V3908	SEAL-O-RING (As Required)
1	6V4876	LUBRICANT (As Required)
1	6V5134	SEAL-O-RING
1	8C5230	SEAL-O-RING
1	8T2998	LUBRICANT-CAM (As Required)
6	9X7317	SEAL-FUEL SYSTEM (As Required)
6	9X7557	SEAL-FUEL SYSTEM (As Required)
1	9Y1758	GASKET-BREATHER
1	0619455	SEAL-O-RING
1	1011635	GASKET
1	1095309	SEAL-ISOLATION
1	1142687	SEAL-O-RING
6	1198784	SEAL-FUEL SYSTEM (As Required)
26	1293184	BOLT-HEX HEAD
1	1402576	PAINT-WHITE (As Required)
6	1442948	CROWN AS.-PISTON (As Required)
6	1523001	BOLT-HEX HEAD
1	1873307	GASKET AS-CYL
6	1979341	RING-PISTON-TOP (As Required)
6	2153198	SEAL-FUEL SYSTEM (As Required)
6	2168570	RING-INTMED (As Required)
1	2173673	SEAL-ISOLATION
6	2382704	RING-PISTON-OIL (As Required)
6	2382712	SKIRT-PISTON (As Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 3*****
1	1S4810	GASKET-OIL DRAIN
1	1S6595	GASKET
1	3K0360	SEAL-O-RING
1	4C4200	PAINT-YELLOW (As Required)
6	4G4972	SEAL-O-RING
1	5P5678	SEAL
1	5P7701	SEAL-O-RING (As Required)
1	5P8211	SEAL-O-RING
2	5S1105	SEAL-O-RING
2	6V3831	SEAL-O-RING
1	6V3908	SEAL-O-RING (As Required)
1	6V4876	LUBRICANT (As Required)
1	6V5134	SEAL-O-RING
1	8C5230	SEAL-O-RING
1	8T2998	LUBRICANT-CAM (As Required)
6	9X7317	SEAL-FUEL SYSTEM (As Required)
6	9X7557	SEAL-FUEL SYSTEM (As Required)
1	9Y1758	GASKET-BREATHER
1	0619455	SEAL-O-RING
1	1011635	GASKET
1	1095309	SEAL-ISOLATION
1	1142687	SEAL-O-RING
6	1198784	SEAL-FUEL SYSTEM (As Required)
26	1293184	BOLT-HEX HEAD
1	1402576	PAINT-WHITE (As Required)
6	1523001	BOLT-HEX HEAD
1	1873307	GASKET AS-CYL
6	1979257	RING-INTMED (As Required)
6	2153198	SEAL-FUEL SYSTEM (As Required)
1	2173673	SEAL-ISOLATION
6	2382717	RING-PISTON-TOP (As Required)
6	2651113	RING-PISTON-OIL (As Required)
6	3223149	BODY AS-PISTON (As Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 4*****
1	1U6396	COMPOUND- O-RING (As Required)
5	2M9780	SEAL-O-RING
1	2N0475	SEAL-O-RING
8	2N2766	LOCKNUT
2	3D2824	SEAL-O-RING
24	3E6772	SEAL-WATER
1	4C4200	PAINT-YELLOW (As Required)
1	4C9505	SEALANT-GASKET (As Required)
1	5E8771	SEAL-O-RING
2	5K9090	SEAL-O-RING-ORFS
1	5P3931	COMPOUND-THREAD (As Required)
1	5P5846	SEAL-O-RING
1	5P8068	SEAL-O-RING
2	6L1650	SEAL-O-RING
4	6V3917	SEAL-O-RING
4	6V4365	SEAL-O-RING
1	6V4876	LUBRICANT (As Required)
2	6V5166	SEAL-O-RING
1	7D7111	SEAL-O-RING
2	7M7273	GASKET-TURBO
5	7M8485	SEAL-O-RING
1	8C3073	SEAL-O-RING
1	8T2998	LUBRICANT-CAM (As Required)
1	8T9022	SEALANT-SILICONE (As Required)
1	9X7317	SEAL-FUEL SYSTEM (As Required)
1	1097411	SEAL-O-RING
1	1178801	SEAL-O-RING
1	1402576	PAINT-WHITE (As Required)
1	1674407	SEAL-O-RING
4	2027530	SEAL
6	2239159	RING-PISTON-TOP (As Required)
1	2245122	GASKET
1	2271204	GASKET
6	2303728	SEAL-FUEL SYSTEM
6	2303775	SEAL-FUEL SYSTEM
6	2382707	RING-PSTN-INT (As Required)
1	2429537	SEAL (As Required)
6	2465659	RING-PISTON-OIL (As Required)
2	2556863	GASKET (As Required)
6	3196715	BODY AS.-PISTON (As Required)
1	3197525	SEAL-PIP
2	3450412	GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 5*****
1	1U6396	COMPOUND- O-RING (As Required)
2	2N0475	SEAL-O-RING
8	2N2766	LOCKNUT
1	3D2824	SEAL-O-RING
24	3E6772	SEAL-WATER
1	4C4200	PAINT-YELLOW (As Required)
1	4C9505	SEALANT-GASKET (As Required)
2	4N3955	GASKET (As Required)
1	5E8771	SEAL-O-RING
1	5K9090	SEAL-O-RING-ORFS
1	5P3931	COMPOUND-THREAD (As Required)
1	5P5846	SEAL-O-RING
1	5P7530	SEAL-O-RING
1	5P8068	SEAL-O-RING
1	6J2245	SEAL-O-RING
2	6L1650	SEAL-O-RING
4	6V3917	SEAL-O-RING
1	6V4876	LUBRICANT (As Required)
1	7D7111	SEAL-O-RING
2	7M7273	GASKET-TURBO
1	7M8485	SEAL-O-RING
1	8C3073	SEAL-O-RING
1	8L2746	SEAL-O-RING (As Required)
1	8T2998	LUBRICANT-CAM (As Required)
1	8T9022	SEALANT-SILICONE (As Required)
1	9X7317	SEAL-FUEL SYSTEM (As Required)
1	1142687	SEAL-O-RING
1	1144427	SEAL-O-RING
1	1178801	SEAL-O-RING
2	1305694	SEAL-O-RING
1	1402576	PAINT-WHITE (As Required)
1	1504104	GASKET
1	1674407	SEAL-O-RING
2	1880210	GASKET-RAIL
4	2027530	SEAL
6	2239159	RING-PISTON-TOP (As Required)
1	2245122	GASKET
1	2271204	GASKET
6	2303728	SEAL-FUEL SYSTEM
6	2303775	SEAL-FUEL SYSTEM
6	2382707	RING-PSTN-INT (As Required)
1	2429537	SEAL (As Required)
6	2465659	RING-PISTON-OIL (As Required)
2	2556863	GASKET (As Required)
6	3294509	BODY AS.-PISTON (As Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 20.0-hour job for Group 1
20.0 hours are allowed for engines not installed in vessels. An additional 21.0 hours will be allowed for an engine that is installed in a vessel. A miscellaneous charge of up to $200 will be accepted to cover any additional parts that may be needed. Include details in claims story.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 19.0-hour job for Group 2
19.0 hours are allowed for engines not installed in vessels. An additional 21.0 hours will be allowed for an engine that is installed in a vessel. A miscellaneous charge of up to $200 will be accepted to cover any additional parts that may be needed. Include details in claims story.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 19.0-hour job for Group 3
19.0 hours are allowed for engines not installed in vessels. An additional 21.0 hours will be allowed for an engine that is installed in a vessel. A miscellaneous charge of up to $200 will be accepted to cover any additional parts that may be needed. Include details in claims story.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 20.0-hour job for Group 4
20.0 hours are allowed for engines not installed in vessels. An additional 21.0 hours will be allowed for an engine that is installed in a vessel. A miscellaneous charge of up to $200 will be accepted to cover any additional parts that may be needed. Include details in claims story.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 20.0-hour job for Group 5
20.0 hours are allowed for engines not installed in vessels. An additional 21.0 hours will be allowed for an engine that is installed in a vessel. A miscellaneous charge of up to $200 will be accepted to cover any additional parts that may be needed. Include details in claims story.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING PISTON RINGS

MODELS INVOLVED - C12, C18, and 3406C Marine Engines

Dear Caterpillar Product Owner:

The piston rings need to be inspected and possibly replaced on the products listed below. The existing piston rings may not be installed properly and may cause the engine to smoke excessively. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 28Oct2010 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 28Oct2010 Service Letter

Rework Procedure

Disassemble the engine to the point of removing the piston and rod groups, as outlined in Disassembly and Assembly instructions SENR1143 (3406C), RENR9405 (C12), and RENR2389 (C18).

Remove piston and rod groups, and place them on a cardboard-lined table.

NOTE: Record the cylinder the pistons are removed from to ensure the pistons are reassembled in the same cylinder from which they are removed.

Perform the following inspections:

Confirm the orientation of the top ring in accordance to the parts book SEBP2520 (3406C), SEBP4002 (C12), SEBP4774 (C18 JKX), SEBP4770 (C18 T2P), SEBP4768 (C18 GES), and SEBP5502 (C18 GBM/GPS). The marking "Up-1" should be facing top of piston.

Confirm the orientation of the intermediate ring in accordance to the parts book (as listed above). The marking "Up-2" should be facing top of piston.

Confirm that the spring within the oil control ring is in place. This ring is symmetrical and can be installed in either orientation.

If any top or intermediate ring is found with incorrect orientation, the ring must be replaced. If the spring within the oil control ring is missing, the ring must be replaced. The ring land of the piston must be thoroughly cleaned and inspected per the Reuse and Salvage Guidelines SEBF8059 for debris or damage prior to installation of the new rings. If damage is seen on the piston, replace the piston.

Clean and inspect cylinder liners prior to installation of the piston and rods.

Reassembly of the engine must be done in accordance with the Disassembly and Assembly guidelines. All fasteners must be properly tightened per the Torque Specifications guide SENR3130.

NOTE: Any rings that are removed from the pistons must be replaced.
NOTE: Apply clean engine oil to the cylinder liner bore, piston rings, outer surface of the piston and rod bearings before reassembly.
NOTE: Ensure that the connecting rod and pistons are installed in the correct cylinder.

Adjust valve lash according to the Testing and Adjusting guide in SISweb.

Touch-up paint as needed.