PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING CONNECTING ROD BOLT TORQUE ON CERTAIN 3606, C280-6, 3608, C280-8, DV-3608, 3612, C280-12, 3616, AND C280-16 MARINE AND PETROLEUM ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING CONNECTING ROD BOLT TORQUE ON CERTAIN 3606, C280-6, 3608, C280-8, DV-3608, 3612, C280-12, 3616, AND C280-16 MARINE AND PETROLEUM ENGINES

Usage:

REBE4303-00

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03Dec2008

U-618

A-513

D-527

O-565

TM-32

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING CONNECTING ROD BOLT TORQUE ON CERTAIN 3606, C280-6, 3608, C280-8, DV-3608, 3612, C280-12, 3616, AND C280-16 MARINE AND PETROLEUM ENGINES
1218 1225		PI31593

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31593" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31593" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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.

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COMPLETION DATE	TERMINATION DATE
30Jun2009	31Dec2009

PROBLEM

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The connecting rod bolts need to be inspected on certain Marine Classification Society (MCS) certified 3606, C280-6, 3608, C280-8, DV-3608, 3612, C280-12, 3616, and C280-16 engines. The connecting rod bolt may fail due to possible improper application of the torque-turn procedure during factory assembly.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3606	8RB00947-00962, 965-971, 973-983, 985-995
C280-6	LDL00100-00105

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*****Group 2*****
3608	6MC00737-00738, 748-749, 753-757, 764-766, 771-779
C280-8	NDT00103, 105-110
DV-3608	1ZD00031-00035

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*****Group 3*****
3612	9RC00453-00463, 465-467, 470-486, 490
C280-12	RDW00103-00104

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*****Group 4*****
3616	1PD00446-00447, 454-455, 457-462, 464, 466-469, 471-484, 486-487, 489-505, 508-510, 516-518, 521, 523, 528, 530, 533-539, 541-542, 544
C280-16	NKB00108-00110, 116-120, 122, 124-125 TDX00102-00110, 115, 117-118, 122, 125-132

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
4	1W0098	BOLT-CONN ROD (As Needed)
4	2050640	NUT (As Needed)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
4	1W0098	BOLT-CONN ROD (As Needed)
4	2050640	NUT (As Needed)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 3*****
4	1W0098	BOLT-CONN ROD (As Needed)
4	2050640	NUT (As Needed)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 4*****
4	1W0098	BOLT-CONN ROD (As Needed)
4	2050640	NUT (As Needed)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Inspect the torque on the connecting rod bolts for each cylinder.

Refer to the attached Rework Procedure

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 13.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 16.0-hour job for Group 2

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 22.0-hour job for Group 3

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 28.0-hour job for Group 4

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING CONNECTING ROD BOLT TORQUE ON CERTAIN 3606, C280-6, 3608, C280-8, DV-3608, 3612, C280-12, 3616, AND C280-16 MARINE AND PETROLEUM ENGINES

MODELS INVOLVED - 3606, C280-6, 3608, C280-8, DV-3608, 3612, C280-12, 3616, and C280-16 Marine and Petroleum Engines

Dear Caterpillar Product Owner:

The connecting rod bolt needs to be inspected on the products listed below. The connecting rod bolt may break due to possible improper application of the torque-turn procedure during factory assembly.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 03Dec2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 03Dec2008 Service Letter

Rework Procedure

BOLT CHECK PROCEDURE

Perform the following steps one cylinder at a time.

1. Place a reference mark (paint mark) on each of the four rod bolt nuts. Extend the mark from the nut onto the cap.

2. Do not loosen the nuts. Using a torque wrench, tighten each nut to 450 +/- 15 Newton meters (332 +/- 11 lb ft). If possible, calibrate the wrench to 450 Newton meters (332 +/- 11 lb ft).

3. Check the reference marks to see if any of the four nuts moved. If the mark on any of the four nuts moved more than 3 mm (when compared to the mark on the cap), replace all four bolts on that rod. Refer to the BOLT REPLACEMENT PROCEDURE and the BOLT INSTALLATION PROCEDURE.

NOTE: Very few rod bolts were tightened incorrectly during factory assembly. If all four rod bolts move more than 3 mm on the first rod that is checked, the torque wrench may not be set correctly. The nuts will not move more than 3 mm if they were installed correctly during assembly. DO NOT REUSE NUTS OR BOLTS THAT ARE REPLACED.

No further action is needed for the cylinder checked if none of the four rod bolts for the cylinder move more than 3 mm.

Repeat the torque check procedure on each cylinder until all rod bolts have been checked for proper torque.

BOLT REPLACEMENT PROCEDURE

Replace the connecting rod bolts two at a time using the following procedure. This will allow the joint to remain together and reduce the chance of debris entering the rod bearing running surface. Refer to Image 1.2.1

Image1.2.1

NOTE: Number (1) and (2) connecting rod bolts are on the same side of the connecting rod as the bearing tab slots.

1. Remove bolts (2) and (3). Replace with new bolts and nuts. Refer to steps 1 and 2 of the BOLT INSTALLATION PROCEDURE for instructions on applying thread lubrication and installing the nuts.

2. Remove bolts (1) and (4). Replace with new bolts and nuts. Refer to steps 1 and 2 of the BOLT INSTALLATION PROCEDURE for instructions on applying thread lubrication and installing the nuts.

BOLT INSTALLATION PROCEDURE

1. Brush 334-0519 Molylube anti-seize lubricant on the bolt threads, nut threads, and nut seating face after the rod bolt is installed in the rod. Do not use Molykote GN anti-seize with this procedure.

2. Turn all four nuts by hand until they contact the cap face. Threading the nuts by hand provides an opportunity to identify problems with the threads. There should be no resistance felt that would indicate thread damage or debris in the threads. If the nuts and/or bolts cannot be threaded by hand, they should be replaced. Do not run the nuts up to the cap face with a torque gun.

3. Tighten nut (1), (4), (2), and then (3) to a torque of 105 +/- 15 Nm (75 +/- 11 lb ft).

4. Tighten nut (1), (4), (2), and then (3) to a torque of 375 +/- 15 Nm (277 +/- 11 lb ft).

5. Retighten nut (2), (3), (1), and then (4) to a torque of 375 +/- 15 Nm (277 +/- 11 lb ft).

6. Turn nut (1), (4), (2), and then (3) an additional 180 +/- 5 degrees.