2003/11/01 Caterpillar

Caterpillar Products:

3500 Family Pumpers

3500 and 3500B Family Generator Sets and Power Modules with Standard Displacement

Engine: Commercial

3500 and 3500B Engines with Standard Displacement

Engine News SEBD9327, November 2003, "Introduction of New Pistons and Remanufactured Cylinder Packs". Disregard this article. The pistons in this article have been cancelled and replaced with new pistons. Refer to the following article for the correct information.

Description of Change:

Illustration 1	g01026917

A new piston has been introduced for 3500 Engines. The forged steel piston is a one-piece piston. A large circumferential slot separates the crown and the skirt. The crown and the skirt remain attached by the strut for the pin bore.

The new top ring is steel and very sensitive to bending. The ring expander tool must be used in order to install the top ring. Failure to use the ring expander tool will result in early hour failure of the piston ring. This will result in engine failure. Refer to table 1 for the part numbers of the tools that are used in servicing the piston.

Table 1

Service Tools
Pt. No.	Description
6V-4020	Piston Ring Expander Gp
6V-4023	Handle As
6V-4024	Guide Ring
1P-1861	Retaining Ring Pliers
1U-7616	Piston Ring Compressor Gp

Adaptable To: The new pistons are a direct replacement for previous pistons that are used in 3500 Engines. The new pistons have the same balance weight as the previous pistons. The new pistons can be used in the same engine with the previous pistons. Table 2 lists the usage of the new piston and rod groups and the former piston and rod groups. The new remanufactured cylinder packs that include the new piston and the former remanufactured cylinder packs are also listed.

Note: The diameter of the eye in the connecting rod has not changed.

Note: The new piston cannot be used in 3500B High Displacement Engines.

Table 2

Status	3500 MUI 3500 with EUI	3500B
New Part	282-0645 Piston and Rod Gp	281-6139 Piston and Rod Gp
Former Part	223-6362 Piston and Rod Gp	223-6363 Piston and Rod Gp
New Remanufactured Part	10R-4378 Cylinder Pack Gp	10R-4343 Cylinder Pack Gp
Former Remanufactured Part	10R-1816 Cylinder Pack Gp	10R-1817 Cylinder Pack

Note: The 282-0645 Piston and Rod Gp, and the 281-6139 Piston and Rod Gp cannot be ordered as groups. Each part must be ordered individually.

Note: Some of the parts that were used with the former pistons are still serviceable for repair. The following parts are still serviceable: 263-8955 Piston Pin, 253-1238 Pin Retainer, 214-6066 Piston Ring (Top), 144-5695 Piston Ring (Intermediate ring) and 223-6361 Piston Ring (Oil). The new pistons reuse the 204-5447 Piston Cooling Jet As and the 193-3282 Retainer As (Piston Cooling Jet) that are part of the piston and rod group.

The 10R-4378 Cylinder Pack Gp and the 10R-4343 Cylinder Pack Gp are ordered as a group. The packs use the 204-5447 Piston Cooling Jet As and the 193-3282 Retainer As (Piston Cooling Jet). Verify that the correct piston cooling jet is installed.

Show/hide table

NOTICE
Failure to install the correct piston cooling jet and retainer will result in inadequate lubrication. This will cause piston seizure and catastrophic engine damage. Install the correct piston cooling jet and the correct retainer.

Table 3 lists all of the parts in the 282-0645 Piston and Rod Gp. Table 4 lists all of the parts in the 281-6139 Piston and Rod Gp.

Table 3

282-0645 Piston and Rod Gp
Pt. No.	Description
282-0644	Piston
263-8955	Piston Pin
253-1238	Retainer (Piston Pin)
214-6066	Piston Ring
144-5695	Piston Ring (Intermediate)
223-6361	Piston Ring (Oil Control)
204-5447	Piston Cooling Jet As
193-3282	Retainer As (Piston Cooling Jet)
0T-0102	Bolt
1B-2790	Bolt
5M-2894	Hard Washer
9M-1974	Hard Washer
144-0725	Rod
107-7330	Connecting Rod Bearing

Table 4

281-6139 Piston and Rod Gp
Pt. No.	Description
278-0247	Piston
263-8955	Piston Pin
253-1238	Retainer (Piston Pin )
214-6066	Piston Ring
144-5695	Piston Ring (Intermediate)
223-6361	Piston Ring (Oil Control)
204-5447	Piston Cooling Jet As
193-3282	Retainer As (Piston Cooling Jet)
0T-0102	Bolt
1B-2790	Bolt
5M-2894	Hard Washer
9M-1974	Hard Washer
144-0725	Rod
107-7330	Connecting Rod Bearing

Table 5 lists all of the parts in the 10R-4378 Cylinder Pack Gp. Table 6 lists all of the parts in the 10R-4343 Cylinder Pack Gp.

Table 5

10R-4378 Cylinder Pack Gp For 3500 MUI and 3500 with EUI Engines
Pt. No.	Description
282-0644	Piston
263-8955	Piston Pin
253-1238	Retainer (Piston Pin)
214-6066	Piston Ring
144-5695	Piston Ring (Intermediate)
223-6361	Piston Ring (Oil Control)
0R-9200	Connecting Rod
211-7826	Cylinder Liner
6V-3774	Gasket Kit

Table 6

10R-4343 Cylinder Pack Gp For 3500B Engines
Pt. No.	Description
278-0247	Piston
263-8955	Piston Pin
253-1238	Retainer (Piston Pin)
214-6066	Piston Ring
144-5695	Piston Ring (Intermediate)
223-6361	Piston Ring (Oil Control)
0R-9200	Connecting Rod
211-7826	Cylinder Liner
6V-3774	Gasket Kit