33810-96J00 Suzuki CABLE ASSY, STARTER MOTOR

November 18, 2003
U-319
A-218
D-237
O-267
beforeor
after failure PRODUCT SUPPORT PROGRAM FOR REPLACINGTHE MAIN BEARING STUDS ON CERTAIN 3606, 3608, 3612, 3616, G3606, G3608,G3612, AND G3616 INDUSTRIAL ENGINES
1201 PS41467
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS41467"as the Part number and "7755" as the Group Number. If administered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If administered after failure, use "96" as theWarranty Claim Description Code and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
November 30, 2005PROBLEM
The main bearing studs need to be replaced oncertain 3606, 3608, 3612, 3616, G3606, G3608, G3612, and G3616 IndustrialEngines. It was discovered that a number of pieces within a particularlot number of bolts were manufactured below the nominal requirements ofthe hardness specification. This problem can cause a bolt to yield morethan the specification allows.AFFECTED PRODUCT
Model Identification Number
*** Group 1 (Inspection Only)***
3606 8RB887, 888
3608 6MC673, 681, 682
G3606 4ZS315, 316, 324, 325,326, 327
G3608 BEN228, 230
G3612 BKE227
G3616 BLB187, 188
*** Group 2 ***
3608 6MC677, 678, 679, 687,688
3612 9RC395, 400, 401
3616 1PD400
G3608 BEN229
G3612 BKE228
G3616 BLB198PARTS NEEDED
Qty
Part Number Description
6-16 1W0121 STUD-TAPERLOACTION REQUIRED
See the attached Rework Procedure.SERVICE CLAIM ALLOWANCES
Product smu Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-500 100% 40.0 0 0 0 0
This is at most a 40.0?hr job.Caterpillar will pay the following labor plustravel and miscellaneous expenses:
Inspection allowance is 2 hrs. per engine. Thoselisted in Group 1 need only to be inspected.
Stud change allowance = 2 hrs. per stud plus 4hrs. per engine (group 2 engines only) for removal and replacement of starters,oil, etc.
All of the main studs on the engines listed belowwill require visual inspection and those studs with a steel lot numberof FC602 must be replaced.
FC602 indication does not mean thestud is necessarily bad, but it is within the lot where it could be bad.All studs in the parts system even those markedFC602 are known good studs. The affected main studs can be identified bya heat treat code stamped on the bottom of the stud, which can be readusing a mirror. The affected products that require replacement of FC602studs are serial number specific and are listed in group 2.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.Attach. (1-Rework Procedure)Rework Procedure
For Vee engines it is not necessary to removethe main bearing caps to replace the main studs. There is enough clearancebetween the main cap and oil pan to allow removing and replacing the studsone at a time with the main cap in place. If replacing several studs alwaysstart at the front of the engine and work towards the rear. On Vee enginesthe crosstie bolts can remain torqued and only the actual stud nut needsto be removed following the procedure for main removal called out in theDisassembly and Assembly Manual.On Inline engines the cap will have to be droppedcompletely out of the way to allow clearance for the stud removal. Againthe work should begin at the front main and progress rearward. During reassemblypay particular attention to the torque sequence.
Lubricate Stud threads with engine oil.