PRODUCT SUPPORT PROGRAM FOR REPLACING CONNECTING ROD BOLTS ON CERTAIN G3606, G3608, G3612, AND G3616 GAS ENGINES

Usage:

SEBE9364-03

October 12, 2005
(Revised March 2007)
U-330
A-241
D-256
O-271

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REPLACING CONNECTING ROD BOLTS ON CERTAIN G3606, G3608, G3612, AND G3616 GAS ENGINES
1218		PS41906

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 "PS41906" 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.

NOTE: This Revised Service Letter replaces the October 12, 2005 (Revised December 2006) Service Letter. Changes have been made to the Affected Product and the Service Claims Allowance.

TERMINATION DATE

October 31, 2007

PROBLEM

The connecting rod bolts need to be replaced in certain G3606, G3608, G3612 and G3616 engines. The 1W0098 connecting rod bolt may experience fretting in the knurled area due to inconsistent clamp loads. The fretting can lead to a fretting fatigue failure. Fretting is less likely to occur on 3600 diesel engines because the diesel piston has 14% less mass than the gas piston.

AFFECTED PRODUCT

Group 1

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Model	Identification Number
G3616	4CG25, 26, 29-32, 34, 37, 39, 41, 46-48, 51-52, 57, 62-63, 65-67, 77, 78, 82-86, 87-91, 94-96, 125-127, 135, 137, 144-145, 148-149, 152-154, 159-165, 174-186, 219-226, 237, 245 BLB174, 176, 177, 184-186, 194-196, 200-204, 205-206, 209-212, 213, 214, 215, 216-219, 222, 226-229, 235, 232, 237, 240, 244

Group 2

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Model	Identification Number
G3612	1YG30-33, 38-41, 45, 48, 49, 57, 66, 67, 69, 76, 79-82, 96, 105-106, 135, 138, 139, 142-143, 154, 176, 209, 210, 229, 230, 238, 239 BKE200-202, 215-216, 218, 220, 222, 224, 238, 240-241, 243-247, 253-254, 288

Group 3

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Model	Identification Number
G3608	4WF56 BEN210, 212-215, 218-220, 224-225, 232-235, 239, 244, 245, 255

Group 4

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Model	Identification Number
G3606	3XF47, 364, 367-369, 375 4ZS286, 303, 317-319, 384, 369-370, 392-393, 395, 398-400

PARTS NEEDED

Group 1

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Qty	Part Number	Description
64	1W0098	BOLT-CONN ROD
64	2050640	NUT

Group 2

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Qty	Part Number	Description
48	1W0098	BOLT-CONN ROD
48	2050640	NUT

Group 3

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Qty	Part Number	Description
32	1W0098	BOLT-CONN RO
32	2050640	NUT

Group 4

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Qty	Part Number	Description
24	1W0098	BOLT-CONN RO
24	2050640	NUT

ACTION REQUIRED

Replace connecting rod bolts and tighten per specification manual SENR5527.

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
Group 1 0-40000	100%	32.0	0	0	0	0
Group 2 0-40000	100%	24.0	0	0	0	0
Group 3 0-40000	100%	16.0	0	0	0	0
Group 4 0-40000	100%	12.0	0	0	0	0
NOTE: This is a 32.0 hr job for Group 1, a 24.0 hr job for Group 2, a 16.0 hr job for Group 3, and a 12.0 hr job for Group 4.