PRODUCT SUPPORT PROGRAM FOR REPLACING THE MAIN BEARING STUDS ON CERTAIN 3606, 3608, 3612, 3616, G3606, G3608, G3612, AND G3616 INDUSTRIAL ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE MAIN BEARING STUDS ON CERTAIN 3606, 3608, 3612, 3616, G3606, G3608, G3612, AND G3616 INDUSTRIAL ENGINES

Usage:

SEBE8577

November 18, 2003
U-319
A-218
D-237
O-267

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE MAIN BEARING STUDS ON CERTAIN 3606, 3608, 3612, 3616, G3606, G3608, G3612, AND G3616 INDUSTRIAL ENGINES
1201		PS41467

NOTE: This Program can 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 "PS41467" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, 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.

TERMINATION DATE

November 30, 2005

PROBLEM

The main bearing studs need to be replaced on certain 3606, 3608, 3612, 3616, G3606, G3608, G3612, and G3616 Industrial Engines. It was discovered that a number of pieces within a particular lot number of bolts were manufactured below the nominal requirements of the hardness specification. This problem can cause a bolt to yield more than the specification allows.

AFFECTED PRODUCT

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Model	Identification Number
* Group 1 (Inspection Only)*
3606	8RB887, 888
3608	6MC673, 681, 682
G3606	4ZS315, 316, 324, 325, 326, 327
G3608	BEN228, 230
G3612	BKE227
G3616	BLB187, 188
* Group 2 *
3608	6MC677, 678, 679, 687, 688
3612	9RC395, 400, 401
3616	1PD400
G3608	BEN229
G3612	BKE228
G3616	BLB198

PARTS NEEDED

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Qty	Part Number	Description
6-16	1W0121	STUD-TAPERLO

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product smu	Caterpillar		Dealer Suggested		Customer Suggested
Product smu	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-500	100%	40.0	0	0	0	0
NOTE: This is at most a 40.0?hr job.

Caterpillar will pay the following labor plus travel and miscellaneous expenses:

Inspection allowance is 2 hrs. per engine. Those listed in Group 1 need only to be inspected.
Stud change allowance = 2 hrs. per stud plus 4 hrs. per engine (group 2 engines only) for removal and replacement of starters, oil, etc.
All of the main studs on the engines listed below will require visual inspection and those studs with a steel lot number of FC602 must be replaced.

NOTE: FC602 indication does not mean the stud is necessarily bad, but it is within the lot where it could be bad. All studs in the parts system even those marked FC602 are known good studs. The affected main studs can be identified by a heat treat code stamped on the bottom of the stud, which can be read using a mirror. The affected products that require replacement of FC602 studs are serial number specific and are listed in group 2.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

For Vee engines it is not necessary to remove the main bearing caps to replace the main studs. There is enough clearance between the main cap and oil pan to allow removing and replacing the studs one at a time with the main cap in place. If replacing several studs always start at the front of the engine and work towards the rear. On Vee engines the crosstie bolts can remain torqued and only the actual stud nut needs to be removed following the procedure for main removal called out in the Disassembly and Assembly Manual.

On Inline engines the cap will have to be dropped completely out of the way to allow clearance for the stud removal. Again the work should begin at the front main and progress rearward. During reassembly pay particular attention to the torque sequence.

Lubricate Stud threads with engine oil.
Torque the 1W0127 Stud to 100 +/- 20 Nm (74 +/- 15 lb-ft).
Install the main cap with the part number towards the front of the block.
Coat all nuts, bolts and washers with engine oil.
Install all nuts and bolts hand tight.
Torque the right side (tab slot side) crosstie bolt to 215 +/- 40 Nm (158 +/- 30 lb-ft.).
Using the Hydraulic tensioner, tension each stud 67,000 +/- 200 Kpa and Hand tighten the nut.
Release tension and repeat previous step.
Tighten the left side (side opposite the tab slot) crosstie bolt to 215 +/- 15 Nm (74 +/- lb-ft).
Torque the right side (tab slot side) crosstie bolt to 1825 +/- 175 Nm (1346 +/- 130 lb-ft.).
Tighten the left side (side opposite the tab slot) crosstie bolt to 1825 +/- 175 Nm (1346 +/- 130 lb-ft.).