PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CONNECTING ROD BOLTS ON CERTAIN G3606, G3608, G3612, AND G3616 ENGINES Caterpillar

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

Usage:

REBE6725-02

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04Mar2011

(Revised 18Aug2011)

U-86

A-69

D-77

O-80

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CONNECTING ROD BOLTS ON CERTAIN G3606, G3608, G3612, AND G3616 ENGINES
1218		PI31850

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31850" 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 "PI31850" 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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NOTE:	This Revised Service Letter replaces the 04 March 2011 (Revised 08 March 2011) Service Letter. Changes have been made to the Service Claim Allowances.

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COMPLETION DATE	TERMINATION DATE
30Sep2011	31Mar2012

PROBLEM

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The connecting rod bolts need to be replaced on certain G3606, G3608, G3612, and G3616 engines. The existing 355-4969 Connecting Rod Bolt could fail due to the bending fatigue of the annulus ring style bolt is not adequate for normal operating conditions.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
G3606	4ZS01322-01441

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*****Group 2*****
G3608	BEN00648-00670

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*****Group 3*****
G3612	BKE00571-00573

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*****Group 4*****
G3616	BLB00618-00658

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
24	2050640	NUT
1	3340519	GREASE-LUB
24	3697181	BOLT AS-CONN ROD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 29% 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*****
32	2050640	NUT
1	3340519	GREASE-LUB
32	3697181	BOLT AS-CONN ROD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 29% 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*****
48	2050640	NUT
2	3340519	GREASE-LUB
48	3697181	BOLT AS-CONN ROD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 29% 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*****
64	2050640	NUT
2	3340519	GREASE-LUB
64	3697181	BOLT AS-CONN ROD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 29% 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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The rod bolts and nuts must be replaced on all cylinders.

Replace the bolts two at a time using the attached Rework Procedure.

NOTE: The attached Rework Procedure will allow the joint to remain closed and reduce the chance of debris entering the rod bearing running surface. The rod cap is not to be removed at any time.

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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 15.0-hour job for Group 1
When the parts order is placed, please reference the service letter number in the customer reference field. If Dealers are unable to order 334-0519 Grease from the Cat system, purchase 67700-CAPT Bel-Ray Molylube Anti-Seize Lubricant directly from the supplier or from an industrial supply house and claim as a miscellaneous expense. One tube is allowed per engine.

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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 20.0-hour job for Group 2
When the parts order is placed, please reference the service letter number in the customer reference field. If Dealers are unable to order 334-0519 Grease from the Cat system, purchase 67700-CAPT Bel-Ray Molylube Anti-Seize Lubricant directly from the supplier or from an industrial supply house and claim as a miscellaneous expense. One tube is allowed per engine.

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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 24.0-hour job for Group 3
When the parts order is placed, please reference the service letter number in the customer reference field. If Dealers are unable to order 334-0519 Grease from the Cat system, purchase 67700-CAPT Bel-Ray Molylube Anti-Seize Lubricant directly from the supplier or from an industrial supply house and claim as a miscellaneous expense. One tube is allowed per engine.

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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 32.0-hour job for Group 4
When the parts order is placed, please reference the service letter number in the customer reference field. If Dealers are unable to order 334-0519 Grease from the Cat system, purchase 67700-CAPT Bel-Ray Molylube Anti-Seize Lubricant directly from the supplier or from an industrial supply house and claim as a miscellaneous expense. One tube is allowed per engine.

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 REPLACING THE 355-4969 CONNECTING ROD BOLTS ON CERTAIN

MODELS INVOLVED - G3606, G3608, G3612, and G3616 Engines

Dear Caterpillar Product Owner:

The connecting rod bolts need to be replaced on the products listed below. The existing rod bolts can fail, damaging the liner, spray jet, rod, or engine block. You will not be charged for the service performed.

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 04Mar2011 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 04Mar2011 Service Letter

Rework Procedure

Bolt Installation Procedure

NOTE: Refer to Image1.1.1 and Image1.1.2. Holes (1) and (2) are on the same side of the connecting rod as the bearing tab slot (5). Hole (1) is on the side next to the serial number pad (6). The cylinder number is located on the bearing tab side of the connecting rod.

1. Loosen the nuts on bolts (2) and (3) and retighten to finger tight. Loosen nuts on bolts (1) and (4) and retighten to finger tight. Keeping the nuts snug to keep the joint closed and prevent debris from entering the bearing.

NOTE: If the crankshaft needs to be rotated in order to remove the bolts there should be a minimum of 105 Nm (75 +/- 10 lb ft) of torque applied to all four bolts in order to prevent the bearing from rotating out of position.

2. Loosen nuts on bolts (2) and (3) and remove bolts for replacement.

3. Clean the 4W-8344 Retainer and clean the bolt heads of the new bolts. The parts must be clean and dry.

4. Install new 369-7181 connecting rod bolts. Apply 334-0519 Grease (67700-CAPT Bel-Ray Molylube Anti-Seize Lubricant) on the bolt threads, nut threads, and nut seating face after the new bolt is installed in the rod.

5. Turn the two new 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.

6. Loosen the nuts on bolts (1) and (4) and remove bolts for replacement.

7. Clean the 4W-8344 Retainer and clean the bolt heads of the new bolts. The parts must be clean and dry.

8. Install new 369-7181 connecting rod bolts. Apply 334-0519 Grease (67700-CAPT Bel-Ray Molylube Anti-Seize Lubricant) on the bolt threads, nut threads, and nut seating face after the new bolt is installed in the rod.

NOTE: DO NOT use Molykote GN with this procedure. The bolt should not be forced into the hole.

9. Turn the two new 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.

NOTE: Do not run the nuts up to the cap face with a torque gun.

Image1.1.1

Image1.1.2

Rod Bolt Tightening Procedure

Follow the connecting rod bolt tightening procedure in the G3600 Family of Engines Specification Manual RENR5907-11 (or newer), and Engine News SEBD9672.

The 369-7181 connecting rod bolts have the Intellifast chip installed in the end of the bolt. This technology allows the installer to verify the bolt stretch after installation. After all bolts are installed and tightened according to the torque process above, the actual bolt load can be verified using the Intellifast reader if one is available.