PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFF LINER CYLINDER COMPONENTS ON CERTAIN PM3516B POWER MODULES THAT HAVE A CERTAIN REMAN ENGINE INSTALLED Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFF LINER CYLINDER COMPONENTS ON CERTAIN PM3516B POWER MODULES THAT HAVE A CERTAIN REMAN ENGINE INSTALLED

Usage:

TEBE4440-01

Show/hide table

12Apr2016

(Revised 19May2016)

B420
D070
D340
D350
E480
E481
J300
P210
R440
U060

Show/hide table

After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFF LINER CYLINDER COMPONENTS ON CERTAIN PM3516B POWER MODULES THAT HAVE A CERTAIN REMAN ENGINE INSTALLED
1239 7555		PS53191

Show/hide table

NOTE:	Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
NOTE:	This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53191" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 12Apr2016 Service Letter. Changes have been made to the Title, Parts Needed, and Action Required.

Show/hide table

TERMINATION DATE

30Apr2018

PROBLEM

Show/hide table

In high load conditions, certain single piece forged steel pistons used in the Single Piece Piston Cylinder System may develop hard deposits at the top land of the piston.

If severe enough, deposits may wear the liner crosshatch, compromising oil control and contributing to additional deposits formation, wear, and blowby.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
PM3516B	BPD00192, 208, 210, 212, 277, 280, 340, 342, 347-348, 365, 392, 396, 519, 610, 687, 719, 746, 759, 772, 785, 872, 887

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
16	1H9696	SEAL-O-RING
4	1S4810	GASKET-OIL DRAIN
4	2W0752	GASKET
3	3P0655	SEAL-O-RING
1	3P6061	GASKET
2	4N1320	GASKET-ADAPTER
16	4S5898	SEAL-O-RING
32	5P0840	SEAL-O-RING
1	5P7818	SEAL-O-RING
8	5P9890	SEAL-O-RING
2	6V1454	SEAL-O-RING
5	6V5066	SEAL-O-RING
16	6V5101	SEAL-O-RING
16	6V9769	SEAL-O-RING
48	7N2046	SEAL-O-RING
1	7N4932	GASKET
1	7N4945	GASKET
16	7N5080	GASKET-MANIFOLD
16	7W8145	GASKET-EXH MANF
4	0336031	SEAL-O-RING
16	1077330	BEARING-CONN ROD
6	1092332	SEAL-O-RING
16	1106991	GASKET-HEAD
1	1111349	GASKET
2	1228856	GASKET AS
16	1272176	SEAL-INTEGRAL
16	1445692	GASKET-PLATE
16	1989926	TUBE AS-OIL JET
16	2236361	RING-PISTON
1	2315128	COVER-VALVE
16	2407032	SEAL-PIP
16	2688154	KIT-GASKET-SFI
16	2720759	SEAL-PIP
16	2720760	SEAL
1	2986387	SEAL-O-RING
64	4200652	SEAL AS-WATER
64	4200653	SEAL AS-WATER
16	4483650	RING-PISTON
16	4483651	RING-PISTON
16	4549920	LINER-CYLINDER
16	4587071	SLEEVE
16	4807093	SEAL-LINER
16	4815615	PISTON AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 10% 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

Show/hide table

This program applies only if the Affected Product is equipped with a Reman Engine that is listed in Image 1.

This program provides support for replacing the Single Piece Cylinder System components with the Cuff Liner and Piston Components System, provided each of the following conditions is met.

1. Verify Oil Consumption exceeds limits listed in LEKQ7390 from the Electronic Media Center (emc.cat.com).

2. Verify Excessive Crankcase Blowby according to REHS7857. Some amount of blowby is generated by every engine and the amount of blowby typically increase with age as parts wear. The repairing dealer must use REHS7857 to determine if the engine is exhibiting sings of excessive blowby. If the Genset is currently "Out-of-Service" and placed in storage, the exception to Crankcase Blowby verification would be to provide photo documentation of the cylinder liner, either by cylinder liner bore scope or the removal of the cylinder head. Provide these photographs to Ben Swim - Customer Service Engineer at email address Swim_Ben_M@cat.com

3. Verify that the engine is seeing an increase trend in Nitration and Oxidation in the last three SOS reports. A trend is defined as at least three consecutive samples with Nitration and Oxidation levels greater than the guidelines listed below.

- Nitration 12 UFM
- Oxidation 24 UFM

If all of these conditions are met, this Service Letter can be applied.

Note: DO NOT mix single piece forged steel pistons designed for the Single Piece Cylinder System with single piece forged steel pistons designed for the Cuffed Cylinder System. Rotating masses and system dynamics are different between the designs and are not compatible within the same engine.

Note: Connecting Rod and Piston Pins are highly reusable. For this reason, the Parts Needed tables do not list these parts. Refer to Image 2 for the ring compressor and installation tools required.

Refer to Disassembly and Assembly, UENR5578.

Note: Install High Flow Piston Spray Jets and an Oil Pump Pressure Regulator cover to increase the engine oil pressure. Because of this update, also increase the oil filter pressure differential warning alarm set point. Reset the Oil Filter Pressure Differential warning set point from 105KPA/15PSI to 138KPA/20PSI.

Show/hide table

Image1

Image2

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-8000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
8001-10000 hrs, 25-37 mo	75.0%	75.0%	0.0%	0.0%	25.0%	25.0%
10001-12000 hrs, 38-50 mo	50.0%	50.0%	0.0%	0.0%	50.0%	50.0%
12001-16000 hrs, 51-60 mo	25.0%	25.0%	0.0%	0.0%	75.0%	75.0%

Show/hide table

NOTE: This is a 95.0-hour job 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.
Since these Power Modules have been repowered by Remanufactured Engines, the product SMU would be the Reman engine SMU. Include the Reman Engine Serial Number in the claim story.

Show/hide table