PRODUCT SUPPORT PROGRAM FOR REWORKING THE CONNECTING ROD BOLTS ON CERTAIN 3606, 3608, 3612, 3616, C280-12, AND C280-16 PETROLEUM ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE CONNECTING ROD BOLTS ON CERTAIN 3606, 3608, 3612, 3616, C280-12, AND C280-16 PETROLEUM ENGINES

Usage:

REBE7535-02

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15Sep2011

(Revised 13Jul2012)

U-389

A-323

D-346

O-340

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE CONNECTING ROD BOLTS ON CERTAIN 3606, 3608, 3612, 3616, C280-12, AND C280-16 PETROLEUM ENGINES
1218 1225		PS43374

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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 "PS43374" 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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NOTE:	This Revised Service Letter replaces the 15Sep2011 (Revised 14Dec2011) Service Letter. Changes have been made to the Parts Needed.

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TERMINATION DATE

30Sep2013

PROBLEM

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The existing 1W-0098 and 355-4969 Connecting Rod Bolts can fail on certain 3606, 3608, 3612, 3616, C280-12, and C280-16 Petroleum Engines. If the existing connecting rod bolt fails, it can damage the liner, spray jet, rod, or engine block.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3616	1PD00045, 47, 60-61, 82-85, 103-104, 110, 113-114, 297-298, 300, 302-305, 313-327, 329-334, 337, 365, 379, 395-397, 454-455, 457-462, 464, 466-467, 469, 471, 473, 480, 483, 489-490, 497, 499-500, 502-505, 507-512, 527-529, 533-539, 541-542, 544-545, 548, 550-551, 554, 556, 565-567, 570-573, 575-576, 578-583, 596-617, 635, 637, 640, 642-643, 645, 647-648, 650, 652, 665-666

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*****Group 2*****
C280-16	NKB00108-00120, 122, 124-133, 136-147, 149-188 TDX00100-00115, 117-132

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*****Group 3*****
C280-12	TSJ00108-00111, 128, 131

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*****Group 4*****
3612	9RC00120, 127, 133-134, 136-139, 147-149, 153-154, 156, 163, 166, 170, 172-173, 206-208, 212, 214, 216, 218-219, 224-226, 240-241, 251-253, 261-285, 292-294, 345-346, 349-350, 353-356, 360-367, 386-393, 396-401, 413-414, 425, 455, 457-461, 465-467, 472, 475-476, 478-480, 482-484, 487, 492-493, 496-497, 512-514, 520-521

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*****Group 5*****
3608	6MC00319, 346-361, 364-378, 394, 415, 438, 508-510, 515-516, 539-542, 544, 551, 553, 555, 559-560, 566-568, 573-574, 581, 610-614, 622, 638, 641, 647-649, 667-670, 702-704, 714, 731-732, 743-745, 757, 764-766, 791

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*****Group 6*****
3606	8RB00319, 334, 336, 339, 373-375, 377, 395, 399, 402, 404, 523-526, 562-564, 643-645, 655, 676-679, 703-705, 708-710, 750, 786, 833, 835-838, 841, 844, 940, 949

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
64	2050640	NUT
1	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 28% 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*****
64	2050640	NUT
1	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 28% 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
1	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 28% 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*****
48	2050640	NUT
1	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 28% 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 5*****
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 28% 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 6*****
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 28% 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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Replace the existing 1W-0098 and 355-4969 Connecting Rod Bolts and Nuts with new 369-7181 Bolts and 250-0640 Nuts. Refer to the attached Rework Procedure for details.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-10000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-20000 hrs, 73-84 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 32.0-hour job for Group 1 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
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. Two tubes are allowed per engine.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-10000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-20000 hrs, 73-84 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 32.0-hour job for Group 2 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
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. Two tubes are allowed per engine.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
0-10000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 24.0-hour job for Group 3 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
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. Two tubes are allowed per engine.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
0-10000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-20000 hrs, 73-84 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 24.0-hour job for Group 4 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
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. Two tubes are allowed per engine.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
0-10000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-20000 hrs, 73-84 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 20.0-hour job for Group 5 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
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. Two tubes are allowed per engine.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 6*****
0-10000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-20000 hrs, 73-84 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 15.0-hour job for Group 6 If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
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. Two tubes are allowed per engine.

PARTS DISPOSITION

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

Rework Procedure

The rod bolts and nuts must be replaced on all cylinders. Replace the bolts two at a time using the following procedure. This 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.

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).

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. Keep the nuts snug to keep the joint closed and prevent debris from entering the bearing.

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

NOTE: For 6- and 8-cylinder engines, it is acceptable to replace bolts (1) and (2) instead of bolts (2) and (3) during this step. Loosen nuts on bolts (1) and (2) and remove for replacement.

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.

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.

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

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.

NOTE: For 6- and 8-cylinder engines, it is acceptable to replace bolts (3) and (4) instead of bolts (1) and (4) during this step. Loosen nuts on bolts (3) and (4) and remove for replacement.

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.

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

BOLT TIGHTENING PROCEDURE

Refer to the new connecting rod bolt tightening procedure in Engine News SEBD9672 and appropriate Specification manual SENR3592 (3612 and 3616 engines), SENR3598 (3606 and 3608 engines), or RENR5082 (all C280 engines).

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 the tightening procedure has been completed, the actual bolt load must be verified using the Intellifast reader.