Technical Information Bulletin, TIBU3917-01, (13 August, 2003) Liner Flange Breakage. Disregard this article. See the article that follows.

There has been a higher than expected failure rate of Liner flanges on engines built approximately in the April 1 thru July 20, 2003 timeframe that use the 159-9778 and 197-9322 Liner. In addition, any repairs completed in this same time period could have had the affected liners included in cylinder packs. We have taken measures to contain the problem liners, including the recall of all of these liners from Morton Parts and Reman that contain the suspect date codes, 90 ? 201 (see figure 1). The analysis of the data collected indicates that only a portion of the liners and engines may be affected by this problem. We have recently determined that liners with Julian dates of 107(April 17) - 133(May 13) inclusively have been verified as being "good" liners and are removed from the investigative range. This may drive a short-term liner part shortage. In the interim, we would ask your help in limiting those repairs that require new liners. This would include scheduled overhauls that could be done at a later date, any proactive repairs related to this issue, etc. Keep in mind that all parts have an underlying failure rate. This includes cylinder liners. You may see liner failures other than flange cracks. This Technical Information Bulletin only addresses the failures that involve flange cracks for engines built during the time period stated above.

To replenish the field, we are rechecking returned liners from Morton Parts and Reman. The good liners from the returns will retain their original stampings but will have additional stamping to indicate that they have been tested and confirmed to be good. The additional stamping (see rework stamp in figure 2) will contain the Cat logo, a 3-digit date code, the number 3 and the letters "DD". These are all good parts and will be placed back into the system.

Liner flange breakage results in rapid coolant loss, engine misfire, and engine overheating.

To help us better understand the extent of the problem, we need the following key parts / information.

If a liner failure occurs:

1. Remove the oil pan and check the date code on all of the Liners.

2. Remove the Cylinder Head.

3. Remove ALL Cylinder Packs that have a suspect date code (90-106 and 134?201).

4. Blow Dry (but do NOT clean) the Liner Flanges.

5. Use a paint stick to label the liners. Identify the "FRONT" of the liner, and identify the cylinder number of the liner.

6. Replace the following parts as they are identified:

- For cylinders WITH cracked Liner(s): Use Reman Cylinder Packs to repair the cylinders.

- For cylinders WITHOUT cracked Liner(s), with a suspect date code: Use new parts to replace ONLY the Liners and Piston Rings.

Reference applicable Service Publications for making the repair.

TC?s: Call the contact for each application as outlined below and report the following information:

1. The S/N of the engine.

2. The engine/machine hours/miles.

2. The ECM Codes that are LOGGED.

3. The Date Codes from the Liners that are cracked (see figure 1).

4. If leaving a message, be sure to leave your name, dealer code, and telephone number.

Machine Applications:

Steve Mc Dowell @ (309) 578-3672

For Marine, Industrial, and Petroleum Engines outside North America, Dealers should contact their MPC. The MPC will forward the information to the contacts identified below:

Marine Applications:

Mike Wade @ (309) 578-4680

Rob Murphy @ (309) 578-8053

Industrial and Petroleum Applications:

Bruce Dudley @ (309) 578-6580

Dan Driscoll @ (309) 578-4629

Electric Power Applications:

Griffin Power Systems Hotline @ (770) 233-3911

Gas Engine Applications:

LEC Service Support Center @ (765) 448-2200

On-highway Truck Applications:

Doug Wilson @ (309) 578-9017

HOLD all parts for the standard warranty retention period.

Note: As you look at he bottom of the liner, the original markings are as follows: Cat logo, part number, 3 digit date code, 1 digit year code, and sequence number.

Figure 1

NOTE: Additional information is stamped on liners that have been rechecked and confirmed as good. They will contain a second Cat Logo, a 3-digit date code, the number 3 and the letters "DD" after the original stamping on the bottom of the liner.

Figure 2