PRODUCT SUPPORT PROGRAM FOR REWORKING THE 1W-0098 CONNECTING ROD BOLTS ON CERTAIN 3606, 3608, 3612, 3616, AND C280-08 ENGINES Caterpillar
PRODUCT SUPPORT PROGRAM FOR REWORKING THE 1W-0098 CONNECTING ROD BOLTS ON CERTAIN 3606, 3608, 3612, 3616, AND C280-08 ENGINES
Usage:
REBE3647-00
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16May2008
D241
D244
L323
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Before/After
(Limited distribution)
PRODUCT SUPPORT PROGRAM FOR REWORKING THE 1W-0098 CONNECTING ROD BOLTS ON CERTAIN 3606, 3608, 3612, 3616, AND C280-08 ENGINES
1218 1225
PS42701
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NOTE:
This Program must 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 "PS42701" as the Part Number
and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.
If administered after failure, use "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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TERMINATION DATE
31May2009
PROBLEM
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The existing 1W-0098 connecting rod bolts can fail on certain 3606, 3608, 3612, 3616, and C280-08 engines. If the existing connecting rod bolt fails it can damage the liner, spray jet, rod, or engine block.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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 and possibly replace the connecting rod bolts. Refer to the attached Rework Procedure.
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SERVICE CLAIM ALLOWANCES
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-100000 hrs
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 20.0-hour job for Group 1
2.o hours per rod. 8.0 additional hours per engine.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-100000 hrs
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 24.0-hour job for Group 2
2.o hours per rod. 8.0 additional hours per engine.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-100000 hrs
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 32.0-hour job for Group 3
2.o hours per rod. 8.0 additional hours per engine.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 4*******
0-100000 hrs
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 40.0-hour job for Group 4
2.o hours per rod. 8.0 additional hours per engine.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
BOLT REPLACEMENT GUIDELINES
1. For engines that have entered service, the rod bolts and nuts must be replaced.
2. For engines that have not entered service, inspect the rod bolts and replace as required. The nuts can be reused.
INSPECTION PROCEDURE
There should be no fretting or nicks on the shank of the connecting rod bolts. This includes the knurled area of the connecting rod boltS. Ensure that the connecting rod boltS meet the guidelines for reusable parts. Reference SEBF8063.
Do not reuse a connecting rod bolt if dimension (X) is more than 329.00 mm (12.953 inch). Refer to Image 1.1.1
Image1.1.1
BOLT INSTALLATION PROCEDURE
Inspect and replace the 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. Loosen bolts (2) and (3) and remove for inspection or replacement, noting which hole the bolts are removed from. Inspect and/or replace the bolts as required. If the bolts pass inspection, install them back in the same hole. If the bolts do not pass inspection, install new bolts. Refer to steps 1 and 2 of the BOLT TIGHTENING PROCEDURE for instructions on applying thread lubrication and installing the nuts.
2. Loosen bolts (1) and (4) and remove for inspection or replacement. Inspect and/or replace the bolts as required. If the bolts pass inspection, install them back in the same hole. If the bolts do not pass inspection, install new bolts. Refer to steps 1 and 2 of the BOLT TIGHTENING PROCEDURE for instructions on applying thread lubrication and installing the nutS.
BOLT TIGHTENING PROCEDURE
Tightening procedure for connecting rod bolts.
NOTE: Number (1) and (2) connecting rod bolts are on the same side of the connecting rod as the bearing tab slots.
1. Put 67700-CAPT Bel-Ray Molylube Anti-Seize Lubricant (this has been direct shipped to the dealer) on the bolt threads, nut threads, and nut seating face after the rod bolt is installed in the rod. DO NOT use Molykote GN with this procedure. For additional informaiton regarding the Molylube Anti-Seize Lubricant contact Lafayette Customer Service @ 765-448-5311.
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 nuts to a torque of 105 +/- 15 Nm (75 +/- 10 lb ft).
4. Tighten nut (1), and then nut (4), and then nut (2), and then nut (3) to a torque of 375 +/- 15 Nm (277+/- 10 lb ft).
5. Retighten nut (2), and then nut (3), and then nut (1), and then nut (4) to a torque of 375 +/- 15 Nm (277 +/- 10 lb ft).
6. Tighten nut (1), and then nut (4), and then nut (2), and then nut (3) an additional 180 +/- 5 degrees.
Make a note of the new connecting rod bolt tightening procedure in all 3600 Family of Engines Specification modules and Disassembly & Assembly modules.
