Inspection And Replacement Of Connecting Rods In Certain 3508, 3512, And 3516 Diesel Engines, And G3508, G3512, And G3516 Gas Engines, And 777D Trucks Caterpillar

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.

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3047" as the Part Number, "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 "PI3047" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: Refer to your Warranty Bulletin for detailed information with regard to Product Improvement Programs.

Completion Date

Termination Date

Problem

Some connecting rod assemblies may have been machined incorrectly. A machining discrepancy in the rod eye bore may not allow the rod eye bushing outside diameter to make complete contact with the rod eye bore. This can reduce the life of the bushing.

Affected Product
Model & Identification Number

3508 (7YG2069, 95Y1016, 96Y1725-1727, 23Z6865, 23Z6867-6871, 23Z6884-6885, 23Z6889, 23Z6892, 68Z903-906, 68Z909 , 68Z912, 68Z914, 69Z745-761)

3508B (7SM77, 7SM82-83)

G3508 (9TG141-144)

3512 (49Y835, 51Y760, 24Z7930-7932, 24Z7935-7948, 24Z7951, 24Z7953-7965, 24Z7969, 24Z7971, 24Z7980-7982, 24Z7985, 24Z7990-7991, 66Z718-721, 66Z1444-1445)

3512B (4TN99, 8RM201-202, 6WN137, 6FL145)

G3512 (7NJ287-290, 7NJ297)

3516 (5SJ542-543, 7CL416, 7CL419-421, 4XF673, 25Z5550-5551, 25Z5553-5555, 25Z5559, 25Z5567, 25Z5569-5574, 25Z5577, 25Z5584-5585, 28Z646, 29Z1227-1230, 67Z1447-1449)

3516B (9AN121, 8KN146-149, 8KN153-154, 7RN464-470)

G3516 (8LD46, 4EK1304-1305, 4EK1307-1313, 4EK1327, 4EK1334)

777D (3PR466-468, 3PR472-478, 3PR480)

Parts Needed

1 - 6I1356 Seal

1 - 6I1357 Seal

1 - 1013281 Rod Assembly

1 - 1077330 Bearing (if necessary)

1 - 1106991 Gasket-Head

1 - 1106992 Gasket

NOTE: The parts are listed as one per failure. As many as 8, 12, or 16 parts may be required depending on the engine model. Additional parts not listed may be required depending on arrangement.

Action Required

See the attached procedure.

Owner Notification

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

Service Claim Allowances

Labor Hour Breakdown

NOTE: For repairs of less than a complete set, 6.0 hours of labor per cylinder are reimbursable.

Allow 1.0 hour labor for testing of an engine and an additional 2.0 hours for setup/tear down.

NOTE: The rod inspection, rod replacement and engine testing setup/tear down labor hours listed above are based on a basic 3500 Series Commercial Engine repaired in a dealer shop. Engines with various attachments, at customer sites or in a vehicle chassis may require additional labor hours. Those additional hours must be explained in the claim details.

Costs incurred for emergency parts orders, for return of connecting rods, oil analysis, equipment needs to complete repairs or engine testing should be listed as other expenses and explained.

Parts Disposition

Return the removed defective connecting rod(s) to:

Package the defective connecting rod(s) in it's original packaging carton for return shipment to Lafayette. Return defective parts within 24 hours of completion of removal from the engine. Call Matt Hannon at (765) 448-5138 or e-mail HANNOMJ with shipping Bill Number, part number, quantity in shipment, and Dealer name and location.

NOTE: Dealers outside of North America should ship by Air Freight.

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

Attach.

(1-Owner Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

Connecting Rod Inspection

- The inspection of the connecting rod date code can be performed by removing the cylinder block side covers (left side typically most accessible) and viewing the date code. Rotation of the crankshaft and use of a mirror and a flash light will assist in viewing the date code on some rods. The date code is located on the side of the side of the rod cap at cap to rod joint. The date code format is YYMXXXX where (YY) is the year, (M) is a letter denoting the month, and (XXXX) is a sequence number. Rods with date codes of 97D1600 Through 97E1000, April and May 1997, need to be replaced in the engine.

Connecting Rod Replacement

- The preferred method to remove/replace the connecting rod is to remove the rod cap through the side cover opening and then remove the cylinder head for removal of the rod/piston assembly.

- Replace the connecting rod as well as the connecting rod bearing, cylinder head gasket, spacer plate gasket, and water seals. Additional seals and associated parts may need replaced depending on the configuration of the engine.

NOTE: When reworking the engine, identify the components removed so that they may be re-installed into the same cylinder as removed from.

Dealer Installed Connecting Rods During Repairs and Rebuilds

- Inspect any new 1013281 Rod Assemblies, 0R4381 Remanufactured Connecting Rod Assemblies, and 0R4445, 0R4446, 0R4447, and 0R4448 Cylinder Packs that have been dealer installed into engines after April 10, 1997 to determine if the connecting rods have date codes of 97D1600 through 97E1000, April and May of 1997.

NOTE: Inspection of engines should be done as quickly as possible. Highest priority should be placed on engines in service or that are scheduled to go into service.

- If the connecting rod has a date code of 97D1600 through 97E1000, April and May of 1997, then replace the connecting rod as well as the connecting rod bearing, cylinder head gasket, spacer plate gasket, and water seals. Additional seals and associated parts may need replaced depending on the configuration of the engine.

NOTE: When reworking the engine, identify the components removed so that they may be re-installed into the same cylinder as removed from.

- Return the defective connecting rods using the instructions listed in the "Parts Disposition" section of this letter.

Test The Engine After Replacing The Defective Connecting Rod (s)

NOTE: It is preferred that the engine is tested either on a dyno or load bank at the dealer shop. Test at the customer sight only if testing cannot be performed at the dealer shop, as installation schedule may make it impractical or impossible.

- Warm the engine to normal operating temperatures, then apply load in steps (25%, 50%, 75%, 100%). Assure the engine is operating properly and has no leaks or noises. Running time of 30 to 60 minutes should be adequate to assure engine operation.

NOTE: If it is not possible to operate at 100% load, then apply as much load as possible.

- Collect an oil sample after the test is completed.

- Mark the sample bottle with the engine serial number, hours on oil, dealer name and dealer code, and return the sample by UPS or DHL to:

If the return of oil samples is not possible, a basic wear metal analysis of the oil can be made locally or by the dealer with the results faxed to Dennis Mahoney at (765) 448-5557.

Factory Built Engines Shipped with Suspect Connecting Rods

- Determine the priority to which the affected engines should be inspected and reworked, if required.

NOTE: Engines which are scheduled for immediate installation/service should be given highest priority.

- All connecting rods in the suspect engines should be inspected for date codes 97D1600 through 97E1000, April and May 1997. Only some connecting rods may need replaced.

- If the connecting rod has a date code of 97D1600 through 97E1000, April and May of 1997, then replace the connecting rod as well as the connecting rod bearing, cylinder head gasket, spacer plate gasket, and water seals. Additional seals and associated parts may need replaced depending on the configuration of the engine.

NOTE: When reworking the engine, identify the components removed so that they may be re-installed into the same cylinder as removed from.

- Return the defective connecting rods using the instructions listed in the "Parts Disposition" section of this letter.

Test The Engine After Replacing The Defective connecting Rod (s)

NOTE: It is preferred that the engine is tested either on a dyno or load bank at the dealer shop. Test at the customer sight only if testing cannot be performed at the dealer shop, as installation schedule may make it impractical or impossible.

- Warm the engine to normal operating temperatures, then apply load in steps (25%, 50%, 75%, 100%). Assure the engine is operating properly and has no leaks or noises. Running time of 30 to 60 minutes should be adequate to assure engine operation.

NOTE: If it is not possible to operate at 100% load, then apply as much load as possible.

- Collect an oil sample after the test is completed.

- Mark the sample bottle with the engine serial number, hours on oil, dealer name and dealer code, and return the sample by UPS or DHL to:

If the return of oil samples is not possible, a basic wear metal analysis of the oil can be made locally or by the dealer with the results faxed to Dennis Mahoney at (765) 448-5557.