PRODUCT SUPPORT PROGRAM FOR REPLACING PISTONS ON CERTAIN 3606, 3608, 3612, AND 3616 INDUSTRIAL ENGINES

Usage:

SEBE8226-02

December 5, 2002
(Revised June 2003)
U-315
A-218
AU-231
S-230
H-229
O-255

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPLACING PISTONS ON CERTAIN 3606, 3608, 3612, AND 3616 INDUSTRIAL ENGINES
7755		PS50592

NOTE: 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 "PS50592" 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.

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.

NOTE: This Revised Service Letter replaces the December 5, 2002 (Revised April 2003) Service Letter. Changes have been made to the Service Claim Allowances.

TERMINATION DATE

December 31, 2003

PROBLEM

In certain circumstances, the 1214068, 1217555, and 4P0399 pistons may experience 3rd land cracking and may not reach the published life expectancy. Pistons need to be replaced on certain 3606, 3608, 3612, and 3616 Industrial Engines.

AFFECTED PRODUCT

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Model	Identification Number
3606	8RB563-571, 573-585, 588-591, 593-610, 612-660, 662-690, 693-712, 714-735
3608	6MC478, 480-499, 501-513, 515-595
3612	9RC176, 178, 185, 187, 189-193, 195-217, 219-228, 230, 232-295
3616	1PD223-231, 236, 238, 240-243, 246-252, 255, 262-266, 268-352

PARTS NEEDED

NOTE: The intention of this program is to replace all pistons, in an engine, when there is a 3rd land failure. It is not to cover engines that may be in the same application, but have not had a failure.

Parts Needed Per Cylinder

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Qty	Part Number	Description
1	1110281	BOTTOM/OIL RING
1	1355149	TOP RING
1	1293581	2nd RING
1	1726772	PISTON AS.
1	1756597	3rd RING

NOTE: Replacing partial sets of pistons due to scheduling is acceptable.

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Qty	Part Number	Description
8	8C5230	SEAL-O RING
2	8C9023	SEAL-O RING
2	6V4314	SEAL-O RING
1	1428615	BEARING

Additional Parts Per Cylinder Depending on Engine Configuration

Spacer Plate Configuration:

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Qty	Part Number	Description
2 Piece Spacer Plate Configuration
8	2N3350	SEAL-O RING
1 Piece Spacer Plate Configuration
8	5P9890	SEAL-O RING

Combustion Gasket:

Distillate with a 1793167 liner uses a 1422826 combustion gasket

Distillate with a 1161042 liner uses a 1457230 combustion gasket

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Piston Hours	Caterpillar		Dealer Suggested		Customer Suggested
Distillate	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-10000	100%	100%	0	0	0	0
10001-20000	75%	75%	0	0	25%	25
20001-30000	50%	50%	0	0	50%	50%
30001-Up	0%	0%	0	0	100%	100%
HFO/Fast Ferry	Parts	Labor	Parts	Labor	Parts	Labor
0-5000	100%	100%	0	0	0	0%
5001-10000	75%	75%	0	0	25%	25%
10001-15000	50%	50%	0	0	50%	50%
15001-Up	0%	0%	0	0	100%	100%
NOTE: This is a 63.4?hr job for the 3606.
NOTE: This is a 83.7?hr job for the 3608.
NOTE: This is a 122.2?hr job for the 3612.
NOTE: This is a 162.0?hr job for the 3616.

PARTS DISPOSITION

Handle parts in accordance with the warranty bulletin on warranty parts handling, with actual pistons with 3rd land crack, being sent to:

R.A. Lofthouse

3600 Customer Services

Lafayette Large Engine Center

Ph. (765)448-5311

Attach. (1-Rework Procedure)

Rework Procedure

Replace the existing 1214068, 1217555, and 4P0399 pistons with the material provided in this program. The cylinder head, rod, and piston assembly must be removed. The unit injector does not have to be removed, but proper blocking must be used when setting the head down to keep from damaging the tip. Refer to the 3600 Disassembly and Assembly manual (3606/08 SENR3600, 3612/16 SENR3594) for the correct procedures to complete the repair.

NOTE: This after failure program is for 3rd land cracking only. The following illustrations are examples of 3rd land cracks. Typically there will be an increase in aluminum in the oil?s SOS results and crankcase pressure will increase, prior to any operational problem. If either of these two signs occurs, inspection of the piston, either by boroscope or visual inspection at the bottom of the liner will give indications of the land cracking.