PRODUCT SUPPORT PROGRAM FOR REPLACING THE CONNECTING ROD BEARINGS ON CERTAIN C175-16 GENERATOR SETS AND LOCOMOTIVE ENGINES OPERATING AT 1800 RPM ENGINE SPEED Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE CONNECTING ROD BEARINGS ON CERTAIN C175-16 GENERATOR SETS AND LOCOMOTIVE ENGINES OPERATING AT 1800 RPM ENGINE SPEED

Usage:

REBE6385-05

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12Aug2010

(Revised 04Jun2014)

U-319

A-248

D-273

O-277

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE CONNECTING ROD BEARINGS ON CERTAIN C175-16 GENERATOR SETS AND LOCOMOTIVE ENGINES OPERATING AT 1800 RPM ENGINE SPEED
1218		PS43141

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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 "PS43141" 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 12Aug2010 (Revised 15Jul2013) Service Letter. Changes have been made to the Title, Problem, and Affected Product.

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TERMINATION DATE

31Aug2015

PROBLEM

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The 3223030/">322-3030 and 3223031/">322-3031 Connecting Rod Bearings in certain C175-16 Generator Sets operating at 1800rpm (60Hz) need to be replaced at EVERY 6,000 hours of engine operation. The 3223030/">322-3030 and 3223031/">322-3031 Connecting Rod Bearings in certain C175-16 Locomotive Engines need to be replaced at EVERY 7500 hours of engine operation. Failure to do so could result in bearing failure and significant machine down time and cost to repair.

AFFECTED PRODUCT

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Model

Identification Number

C175-16

R1X00101-00113

WYB00100-00107, 109-112, 114-117, 125-126, 129, 135-136, 138, 140, 142-172, 175-177, 186, 189, 191, 193-198, 201-203, 206-209, 213-215, 218, 221-222, 231-233, 247, 249-252, 260, 262, 264-267, 271-306, 308, 319, 322-323, 325, 327-331, 334-338, 340, 342, 344-353, 355-357, 359-362, 364-365, 371, 375-377, 379, 387, 389-390, 393-394, 396-397, 399-409, 420, 426-434, 436-439, 442-450, 452, 454, 456-465, 467, 469, 472, 474-476, 478-481, 483-489, 492-495, 497, 499-500, 502, 504, 506, 508, 511, 514-515, 517-518, 520-536, 538, 540-548, 550-552, 554-555, 557, 560, 563-565, 567, 569, 571, 574, 576, 578-581, 586, 589, 592, 597, 600-603, 605, 607-608, 610-626, 632, 639, 641, 643, 647, 649-656, 658-660, 662-669, 671-675

PARTS NEEDED

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Qty	Part Number	Description
1	2H3928	SEAL-O RING
6	3E6747	SEAL-O-RING
1	3E6751	SEAL-O-RING
2	3P0655	SEAL-O-RING
2	3P1155	SEAL-O-RING
2	4H7869	GASKET
32	5P6718	SEAL-O-RING
6	6V1196	SEAL-O-RING
10	6V2701	SEAL-O-RING
2	6V3835	SEAL-O-RING
1	6V5055	SEAL-O-RING
1	6V8002	SEAL-O RING
1	6V8997	ADAPTER-STR
4	8C3078	SEAL-O-RING
16	8C3132	SEAL-O RING
64	8T2223	BOLT-SOCKET HD
4	8T7524	SEAL-O-RING-STOR
3	8T7876	SEAL-O-RING
16	8T9524	SEAL-O-RING
9	1090077	SEAL-O-RING
1	1097411	SEAL-O-RING
4	1128186	SEAL-O-RING
1	1291610	SEAL-O-RING
1	2095798	SEAL-O-RING
23	2287090	SEAL-O-RING-ORFS
6	2287091	SEAL-O-RING-ORS
16	2287092	SEAL-O-RING-ORFS
3	2287093	SEAL-O-RING-ORFS
2	2287100	SEAL-O-RING-STOR
1	2287101	SEAL-O-RING-STOR
14	2287102	SEAL-O-RING-STOR
1	2287103	SEAL-O-RING-STOR
23	2287105	SEAL-O-RING-STOR
5	2287106	SEAL-O-RING-STOR
16	2287108	SEAL-O-RING-STOR
16	2435741	SEAL-FUEL SYSTEM
16	2435742	SEAL-FUEL SYSTEM
4	2473796	GASKET
16	2487687	SEAL
1	2588734	SEAL-O-RING
13	2588738	SEAL-O-RING
20	2594597	SEAL-O-RING
16	2720759	SEAL-PIP
8	3223030	BEARING
8	3223031	BEARING
96	4287386	BOLT AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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Refer to attached rework procedure.

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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%
0-5000 hrs, 0-24 mo	0.0%	0.0%	100.0%	100.0%	0.0%	0.0%
5001-24000 hrs, 25-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 120.0-hour job

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PARTS DISPOSITION

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Return removed connecting rod bearings via the Send-It-Back system. A parts return request will be generated when submitting a claim with this program PS43141 as the part causing failure.

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

Rework Procedure

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Replace all 3223030/">322-3030 and 3223031/">322-3031 Connecting Rod Bearings in C175-16 Generator Sets at EVERY 6,000 hours of engine operation. Refer to RENR7466 "Connecting Rod Bearings - Remove and Install" for bearing removal and installation instructions.

The piston support tooling referenced in the Disassembly and Assembly guide is strongly recommended for this procedure. The part number is 369-4008.

The Parts Needed list includes the gaskets, O-rings, and other items that need to be replaced due to their one-time use requirement.

Refer to Reuse and Salvage Guidelines, SEBF9109, "Handling Procedures for the Components of the Common Rail Fuel System" for addition information in handling fuel system parts.

NOTE: Each rod end and rod cap surface must be properly cleaned once the old bearing is removed. It is absolutely necessary that the surfaces be cleaned using only brake cleaner and a lint-free cloth. EXERCISE CARE SO AS NOT TO LEAVE ANY DIRT OR DEBRIS FROM THE CLOTH ON THE FRACTURE-FACE SURFACES OF THE ROD AND CAP!
PROTECT OIL PASSAGES ON THE CRANK JOURNALS FROM CLEANING FLUID ENTRY!

This service letter includes all new 428-7386 Connecting Rod Bolts. Lubricate each bolt with 334-0519 Molylube, fully coating under the head of the connecting rod bolt (1), the elastomer rings on the center of the bolt shank (2), and the threads of the bolts (3). See image 1.2.1 below.

Note: The 428-7386 Bolts should only be cleaned with a dry lint-free towel and if needed, 4C-6796 Mineral Spirits is one solvent that is compatible with the elastomer rings. Never clean the bolts in a parts washer or with solvents such as brake cleaner or carburetor cleaner. They could damage the elastomer rings.

Note: A video demonstrating the proper assembly procedure for the rod bolts is available at https://dealer.cat.com/Service-Training/Instructional-Videos

Image1.2.1

Ensure the connecting rod cap and rod end bolt holes are dry and free of debris. Install six lubed connecting rod bolts through the washer plates and into the connecting rod cap by simultaneously rotating and pushing each bolt. It is required to slowly rotate the bolt during installation to prevent damage to the elastomer rings. Do not exceed 700 RPM with a rundown tool. This could damage the elastomer rings.

Install the connecting rod cap over the crank journal. Engage the threads of all six bolts before the joint is drawn closed on either side. The order of engaging the threads should be by bolt number 1-2-3-4-5-6 (see image 1.3.1 for bolt numbering). Engaging bolts 1 and 2 first helps center the cap with the rod such that bolts 3-4-5-6 will go in straight and not cause damage to the starting thread. The bolt should be rotated slowly (less than 700 RPM) during installation to prevent damage to the elastomer rings. Do not tap the bolt since an impact between the end of the bolt and the start of the threads could cause thread damage.

Follow the connecting rod bolt torque procedure documented below. This is the torque procedure for all type 1 connecting rods. Image 1.3.1 below shows the connecting rod bolt numbering sequence as viewed from beneath the engine. Note: Bolt (1) is always identified as the center bolt on the bearing tab side of the connecting rod.

Image1.3.1

Step 1: Tighten bolts (1) and (2) to a torque of 105 +/- 5 N.m (77 +/- 4 lb ft).
Step 2: Tighten bolts (3) and (4) to a torque of 105 +/- 5 N.m (77 +/- 4 lb ft).
Step 3: Tighten bolts (5) and (6) to a torque of 105 +/- 5 N.m (77 +/- 4 lb ft).

Step 4: Repeat Steps 1 through 3

Step 5: Turn bolts (3) and (4) for an additional 90 +/- 5 degrees.
Step 6: Turn bolts (5) and (6) for an additional 90 +/- 5 degrees.
Step 7: Turn bolts (1) and (2) for an additional 90 +/- 5 degrees.