PRODUCT SUPPORT PROGRAM FOR REPLACING THE CONNECTING ROD BEARINGS ON CERTAIN G3612 AND G3616 ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE CONNECTING ROD BEARINGS ON CERTAIN G3612 AND G3616 ENGINES

Usage:

SEBE9051

February 4, 2005
U-32
D-27
O-29

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*Before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE CONNECTING ROD BEARINGS ON CERTAIN G3612 AND G3616 ENGINES
0010		PS41618

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 "PS41618" 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: Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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

December 31, 2006

PROBLEM

The connecting rod bearings used in high compression ratio G3612 and G3616 engines require replacement at less than the projected service interval. A new rod bearing design has been developed to improve the service life for this application.

AFFECTED PRODUCT

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Model	Identification Number
G3612	1YG154, 176-178, 192
G3616	4CG127, 135, 137, 144-145, 148-149, 152-154, 159-165, 174-178187, 192-193, 196-199, 209-212, 217-224, 226, 244-245 BLB174-176, 178-179, 184, 194-196, 209-210, 213, 222

PARTS NEEDED

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Qty	Part Number	Description
G3612
12	2272902	BEARING
G3616
16	2272902	BEARING

ACTION REQUIRED

The rod bearing currently installed in the engine should be replaced after 15,000 hours of operation and no greater than 20,000 hours of operation. Follow all existing rod bearing removal and replacement guidelines for the G3600 engine.

This product support program will only cover the replacement of the 101-4181 and 192-7870 rod bearing. After installation of the 227-2902 connecting rod bearing per this support program, the customer should follow a 20,000 hour inspect/replace maintenance practice. Experience may dictate that the new bearing material will continue to operate at greater than 20,000 hours of operation. Contact your local servicing dealer for inspection support of the 227-2902 rod bearing at the first 20,000 hour maintenance interval.

NOTE: Use the latest connecting rod bolt torque procedure as described in the Sept. 2004 Engine News Article, SEBD9337-00, "A New Tightening Procedure For Connecting Rod Bolt Is Being Used".

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
G3612
Engine Hrs: 0-20,000 Part Hrs: 15-20,000	50%	12 hrs	0	0	50%	12 hrs
G3616
Engine Hrs: 0-20,000 Part Hrs: 15-20,000	50%	16 hrs	0	0	50%	16 hrs
NOTE: This program should be applied when the rod bearings have between 15,000 ? 20,000 hours. Do not exceed 20,000 hours of operation.
NOTE: The customer is responsible for all maintenance costs associated with bearing replacement at all normally expected overhaul periods.