Installation Of The Top And The Intermediate Piston Rings On G3600 Engine Pistons Caterpillar

Installation Of The Top And The Intermediate Piston Rings On G3600 Engine Pistons

Usage:

ENGINESG3606 (3XF),
G3608 (4WF),
G3612 (1YG),
G3616 (4CG) ENGINES

Problem:

During a recent quality check the intermediate piston ring was found to be installed upside down on all the pistons in a G3600 Engine. This occurred because the identifying paint stripe was placed on the wrong side of the ring gap during manufacture. Factory personnel were using the paint stripe to orient the ring on the piston. Extremely high oil consumption resulted from all the intermediate piston rings being installed upside down.

Solution:

DO NOT USE THE PAINT STRIPE AS A REFERENCE TO ORIENT THE PISTON RINGS DURING ASSEMBLY. The intermediate and top piston rings have always been marked as follows:

* The intermedate ring has "UP-2" etched on the top surface of the ring.

* The top ring has "UP-1" etched on the top suface of the ring.

Use the "UP-1" and "UP-2" as reference marks to correctly orient the top and second piston rings respectively.

The Disassembly and Assembly Module, SENR4259-03, G3606 and G3608 Engines, (part of the Service Manual, SENR4255), "Piston and Rod Installation", includes incorrect information on Page 183, in Step 11b. and 11c.

The Disassembly and Assembly Module, SENR5535-03, G3612 and G3616 Engines, (part of the Service Manual, SENR5500), "Piston and Rod Installation", includes incorrect information on Page 207, in Step 11b. and 11c.

The correct Steps 11b. and 11c. follow:

11b. The second piston ring must be installed with the "UP-2" mark toward the top of the piston.

11c. The top piston ring must be installed with the "UP-1" mark toward the top of the piston.

The Specifications Module, SENR4257-03, G3606 and G3608 Engines, (part of the Service Manual, SENR4255), "Piston and Rings", includes incorrect information on Page 42, in Table 3, Footnotes (1) and (2).

The Specifications Module, SENR5527-04, G3612 and G3616 Engines, (part of the Service Manual, SENR5500), "Piston and Rings", includes incorrect information on Page 43, in Table 3, Footnotes (1) and (2).

The correct Footnotes (1) and (2) follow:

(1) The top ring must be installed with the "UP-1" mark toward the top of the piston.

(2) The intermediate ring must be installed with the "UP-2" mark toward the top of the piston.