PRODUCT SUPPORT PROGRAM FOR REWORKING PLUGGED CROSS DRILL FUEL PASSAGES IN HEADS ON CERTAIN G3606, G3606B, G3608B, G3612, G3612B, AND G3616B ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING PLUGGED CROSS DRILL FUEL PASSAGES IN HEADS ON CERTAIN G3606, G3606B, G3608B, G3612, G3612B, AND G3616B ENGINES

Usage:

TEBE8246-00

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28Sep2018

U-545

A-398

O-484

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING PLUGGED CROSS DRILL FUEL PASSAGES IN HEADS ON CERTAIN G3606, G3606B, G3608B, G3612, G3612B, AND G3616B ENGINES
1100 0703		PS46017

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS46017" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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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TERMINATION DATE

30Sep2020

PROBLEM

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The existing pre-chamber cross-drilled fuel passage plugs can loosen in the cylinder heads on certain G3606, G3606B, G3608B, G3612, G3612B, and G3616B Engines. If the existing plugs loosen it can lead to a misfiring cylinder or in certain circumstances leak fuel.

AFFECTED PRODUCT

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Model	Identification Number
G3606	4ZS02209-02210
G3606B	JFE00156-00207, 209, 211, 214, 216-219
G3608B	XH700134-00165
G3612	BKE00803-00811
G3612B	BB200113-00114, 116-122, 701-705
G3616B	ZZY00148-00160, 701-707

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Using Cat supplied tools, tighten the plugs in question to 10 Nm. Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-25000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 5.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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Pipe Plugs in question are not to be loosened.
Tools provided are calibrated to 10 Nm.
Use tool A to torque the plug in the top of the head under the rocker cover.
Use tool B to torque the plug in the side of the head.

Tools shown will be provided and distributed to individual servicing dealers for completion of this letter. Any questions concerning these tools or their use should be directed through the Dealer Technical Communicator (TC) to CPI number 389903 through CPI Feedback within the Service Information Management System (SIMSi).

Image1.1.1

1) Remove rocker cover.

2) Remove entire fuel tube and fitting assembly between the needle valve and the head to allow access to the internal pipe plug.

3) Loosen rocker base.

4) Without removing water manifold, raise and support rocker base for access to the plug beneath rocker cover.

Image1.2.1

5) Tighten plug with the long, angled tool provided, (tool A).

6) Reinstall rocker base, cover, and fuel tube previously removed. Care should be taken when reinstalling rocker base to make sure lower o-ring is positioned correctly in base before tightening.

7) In same manner as above, tighten plug in side of head with the short straight tool provided, (tool B).