PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE PISTON ASSEMBLIES IN CERTAIN 3044CT ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE PISTON ASSEMBLIES IN CERTAIN 3044CT ENGINES

Usage:

REBE2144-00

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19Jul2007

U-345

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE PISTON ASSEMBLIES IN CERTAIN 3044CT ENGINES
1225 1218		PI31306

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31306" as the Part Number and "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 "PI31306" as the Part Number, "7751" as the Group Number, "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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COMPLETION DATE	TERMINATION DATE
31Jan2008	31Jul2008

PROBLEM

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Specific 3044C engines have been assembled with piston assemblies that are potentially defective. A machining process error has resulted in some pistons having a stress raiser which can lead to the piston cracking.

AFFECTED PRODUCT

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Model	Identification Number
3044	34403250-03303, 3470-3541, 3544-3750, 3985-4056

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Remove pistons and replace with new pistons. Please refer to the attached Rework Procedure. Needed parts have been direct shipped for repairs to be made.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 10.0-hour job

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PARTS DISPOSITION

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

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

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE PISTON ASSEMBLIES IN CERTAIN 3044CT ENGINES

MODELS INVOLVED - Certain 3044CT Engines

Dear Caterpillar Product Owner:

The Pistons need to be reworked on the products listed below. The existing Piston can crack, causing engine failure. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 19Jul2007 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 19Jul2007 Service Letter

Rework Procedure

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Action Required: Follow the attached rework procedure.

Mount the engine in a suitable engine mount / turnover to enable the following rework activities to be carried out.
The engine can be cleaned if necessary before commencing the rework ? see section "Engine ? Clean" in the OMM.
Make sure a suitable tray is placed under the engine to catch any fluids that may be lost during the rework (fuel, oil & coolant).

Guidance on all of the operations below is contained in RENR7582 on SISWEB.

1. Remove the turbocharger assembly ? SMCS 1052-011

2. Remove the high-pressure fuel lines ? SMCS 1252-010

3. Remove the fuel injection nozzles ? SMCS 1254-011

4. Remove the glow plugs (heater plugs) from the cylinder head ? SMCS1412-010

5. Disconnect the crankcase breather from the valve mechanism cover ? SMCS 1317-010

6. Remove the valve mechanism cover - SMCS 1107-00

7. Remove the rocker shaft and pushrods ? SMCS 1208-011

8. Loosen and remove the cylinder head retaining bolts in the order shown in SMCS1100-011.

9. Remove the cylinder head ? using suitable lifting eyes and lifting equipment, the cylinder head weighs approximately 50Kg. Place the cylinder head on a clean, dry surface where the mating face will not get damaged ? SMCS 1100-011

10. Remove the cylinder head gasket.

11. Use a suitable tool to remove the carbon ridge from the top inside surface of the cylinders ? SMCS 1412-010

12. Turn the engine over to gain access to the sump.

NOTE: There is the possibility of fluids draining from the engine at this point.

Loosen and remove the 24 setscrews that secure the sump to the cylinder block, remove the sump pan and carrier joint ? SMCS 1302-010

13. Remove the oil suction tube assembly and sealing O-ring

14. Use a 46mm socket or suitable tooling to rotate the crankshaft until a pair of pistons are at their lowest point in the cylinder bore, slacken and remove the connecting rod cap nuts and lower bearing shell. Keep all parts together as a single assembly ? mark the connecting rods and caps if necessary to identify them ? SMCS 1225-011

15. Put adhesive tape or rubber sleeves over the connecting rod studs to protect the crankshaft journals from damage, push the piston / connecting rod assembly to the top of the cylinder block ? support the assembly as it is withdrawn.

16. Repeat this process for all four piston / connecting rod assemblies.

17. Use suitable circlip pliers to remove the two retaining rings holding the piston pin in place. Push out the piston pins from the pistons ? if the pins are tight raise the temperature of the piston to 45 degrees C in hot water ? do not use a torch.
Use a suitable press and carefully remove the pins.

18. Fit the new set of pistons to the connecting rods ? if necessary heat the pistons as above to aid the fitting of the pistons.
NOTE: Ensure the correct orientation of piston / rod and that the ends of the pin retaining rings are facing down.

19. Using a ring expander carefully fit the oil control ring to the lower groove, the intermediate compression ring to the middle groove and the compression ring to the top groove. The identifying letter "R" or "T" must face the top of the piston.

20. Re-assemble the engine in the reverse order to those above - using the instructions in RENR7582. Use the replacement parts listed in Parts Needed.

Following the replacement of the pistons and associated parts, the engine will need to be hot tested ? please follow the instructions below: NO LOADING OF THE ENGINE IS NECESSARY DURING HOT TEST.

21. Lift the engine on to a suitable test bench. Fill the engine with 9.5 litres of engine oil filled through the oil filler cap in the valve mechanism cover. Confirm the oil level on the dipstick after filling.

Image1.1.1

22. Connect suitable exhaust ducting to the exhaust manifold outlet (screw size is M8 x 1.25mm) and tighten to a torque of 15Nm +/- 5 Nm.

Image1.2.1

23. Connect a suitable air cleaner to the induction manifold ? the outer diameter is 60.00mm.

Image1.3.1

24. Connect the fuel feed hose to the fuel injection pump inlet ? diameter 8.00mm.

Image1.4.1

25. Connect one coolant hose to the thermostat outlet ? diameter 42.00mm and connect the second coolant hose to the water pump inlet ? diameter 42.00mm.

Image1.5.1

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26. Remove the fan (if fitted) ? remove the four bolts and replace them with 4 bolts size M8 x 1.25mm for testing only, tighten these to a torque of 18.5Nm +/- 3.5 Nm.

Image1.6.1

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27. Install wiring to the starter motor ? the upper connection is the supply side.

Image1.7.1

28. Connect a 12 Volt feed to the fuel injection pump fuel solenoid via the connector shown.

Image1.8.1

29. Install a temporary cover plate over the PTO (if fitted) ? this is to prevent oil leaking around the timing case.

30. Install an oil pressure gauge into the oil pressure rail ? this replaces the oil pressure switch.

31. Open the coolant /fuel valves, power the starter motor and crank the engine until oil pressure is seen. Power the fuel pump solenoid and run the engine.

32. Run the engine at a low idle speed (960 RPM ) for 5 minutes and check that the minimum oil pressure is more than 118 Kpa and that there is no abnormal engine noise.

33. After 5 minutes set the engine speed to 1900 RPM for an additional 5 minutes. After this period check the engine for signs of water / oil / fuel leakage ? and rectify is necessary.

34. After 5 minutes run the engine at high idle speed (2860 RPM) for an additional 5 minutes and again check for signs of leakage. Ensure that the low idle speed is 960 RPM +/- 20 RPM and that the high idle speed is 2860 RPM +/- 25 RPM.

35. Stop the engine by disconnecting the power feed to the fuel pump solenoid. Isolate the coolant and fuel hoses. Drain the coolant by removing the coolant drain plug in the crankcase water jacket. Care should be taken, as the coolant temperature will be high. After draining the coolant, replace the drain plug and tighten to a torque of 39Nm +/- 5Nm. Disconnect the coolant hoses from the engine.

36. Carefully disconnect the fuel feed line and catch any fuel that is present.
Remove the oil drain plug from the oil pan and drain the oil into a suitable container. Replace the oil drain plug and tighten to a torque of 39.5Nm +/- 4.5Nm.

37. Remove the temporary PTO cover (if fitted).

38. Remove the four temporary bolts from the fan drive hub and refit the fan (if previously fitted). Tighten the four setscrews to a torque of 18.5Nm +/- 3.5Nm.

39. Remove the wiring from the fuel pump solenoid and starter motor. Remove the oil pressure gauge and replace the original oil pressure switch and tighten to a torque of 17.5Nm +/- 2.5Nm.

40. Disconnect the induction / exhaust pipe work from the engine.