PRODUCT SUPPORT PROGRAM FOR REPLACING PISTONS AND PISTON RINGS ON CERTAIN C13 ENGINES INSTALLED IN VARIOUS 345C AND 345D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING PISTONS AND PISTON RINGS ON CERTAIN C13 ENGINES INSTALLED IN VARIOUS 345C AND 345D EXCAVATORS

Usage:

REBE5184-01

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22Jun2009

(Revised 09Sep2009)

U-228

A-195

D-195

O-201

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING PISTONS AND PISTON RINGS ON CERTAIN C13 ENGINES INSTALLED IN VARIOUS 345C AND 345D EXCAVATORS
1215 1201 1225		PS51683

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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 "PS51683" 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.

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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 22Jun2009 Service Letter. Changes have been made to Parts Needed.

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TERMINATION DATE

30Jun2010

PROBLEM

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The existing piston and piston ring package can cause an unacceptable level of engine oil consumption on certain 345C and 345D Excavators. If certain operating conditions coupled with certain ambient conditions are met, carbon buildup can occur on the piston which will lead to decreased piston ring effectiveness resulting in increased oil consumption. The improved piston and ring design is less sensitive to these operational and ambient conditions.

AFFECTED PRODUCT

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Model	Identification Number
345C	BWY00102-00327 DHP00248-00463 ESD00168-00234 GPH00130-00464 JAR00280-00330 MDC00217-00242 PJW00350-02257 RFN00143-00173 SPC00221-00271 TBA00133-00449 TDG00250-00396 WDE00142-00167
345C FM HEEL	A3L00100-00105
345C L	ELS00151-00177 FPC00101-00146 GBH00162-00192 GCL00161-00278 LYS00133-00186 S5M00221-00302 TAJ00210-00338
345C MH FCR	M2R00151-00222
345C MH HCR	D3S00171-00173 MTE00131-00132
345D	NEG00179
345D L	DPA00176 EEH00221-00222 JKN00109-00110 RAJ00231-00233 RGG00101-00105 YEE00241

PARTS NEEDED

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Qty	Part Number	Description
26	2S5658	WASHER-HARD
3	5P5678	SEAL
6	9X7317	SEAL-FUEL SYSTEM
6	1043560	SEAL-LINER
12	1152973	BOLT-CONN ROD
6	1161089	BEARING-ROD
6	1979330	LINER-CYLINDER
8	2104460	BOLT-HEX HEAD
1	2173673	SEAL-ISOLATION
1	2219392	GASKET-CYL HEAD
1	2295711	SEAL-ISOLATION
6	2303728	SEAL-FUEL SYSTEM
6	2303775	SEAL-FUEL SYSTEM
26	2421811	BOLT-HEX HEAD
6	2651113	RING-PISTON-OIL
1	2720389	SEAL
6	3033141	RING-PSTN-TOP
6	3250608	BODY AS.-PISTON
6	3316025	RING-PSTN-INTMD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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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Track the engine oil consumption and complete and daily engine oil consumption log.

- If engine oil consumption is determined to be in the investigate range, replace the cylinder liners, pistons, and piston rings in the Affected Product.

Before this service letter can be performed, an "Excessive Engine Oil Consumption" log must be filled out and oil consumption must be within the investigate range as defined in Warranty Bulletin 3.18 before this service letter can be applied.

Refer to Global Warranty Bulletin 3.18 for instructions on how to monitor oil usage.

The Daily Oil Consumption Log must be attached with the claim for the work being performed under this service letter.

NOTE: 227 liters fuel/liter of oil, is the incorrect quantity for the investigate range. The correct specification for investigate is 240 liters fuel/liter of oil. This is in the process of being corrected within the bulletin.

Refer to the attached Rework Procedure for details.

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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%
0-2000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
2001-4000 hrs, 13-24 mo	65.8%	75.0%	0.0%	0.0%	25.0%	25.0%
4001-6000 hrs, 25-36 mo	33.3%	50.0%	0.0%	0.0%	50.0%	50.0%
6001-8000 hrs, 37-48 mo	33.3%	0.0%	0.0%	0.0%	50.0%	100.0%

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NOTE: This is a 50.0-hour job
The Daily Oil Consumption Log must be attached with the claim for the work being performed under this service letter.

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PARTS DISPOSITION

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

Rework Procedure

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Refer to global warranty bulletin 3.18 for instructions on how to monitor oil usage. To access the global warranty bulletin 3.1.8:
- Refer to; https://warranty.cat.com
- Select "Warranty Service Guide" from the scrolling options. Image 1.1.1
- Scroll down the page to the appropriate section and select "3.18 Excessive Engine Oil Consumption". Image 1.1.2

Image1.1.1

Image1.1.2

Before this service letter can be performed, an "Excessive Engine Oil Consumption" log must be filled out and oil consumption must be within the investigate range as defined in Warranty Bulletin 3.18 before this service letter can be applied.

NOTE: 227 liters fuel/liter of oil, is the incorrect quantity for the investigate range. The correct specification for investigate is 240 liters fuel/liter of oil. This is in the process of being corrected within the bulletin.

To access the Daily Oil Consumption Log:
- Refer to; https://warranty.cat.com
- Select the Machines tab. Image 1.2.1

Image1.2.1

- Select "Learn More" from the Warranty and Equipment Protection Plan Forms. Image 1.3.1

Image1.3.1

- Select the Daily Oil Consumption Log. Image 1.4.1

The Daily Oil Consumption Log must be attached to the claim for the work being performed under this service letter.

Image1.4.1

Procedure:

NOTE: It is acceptable to perform this rework in chassis when possible. In many applications it may be necessary to remove the engine from the machine to perform the rework.

Refer to the appropriate Disassembly and Assembly Manual for additional detailed information when performing the Rework Procedure.

1. Drain engine fluids according to appropriate guidelines.

2. Remove valve cover from engine.

3. Remove rocker arm mechanisms from cylinder head.

4. Remove valve cover base from cylinder head.

5. Remove fuel injectors from cylinder head.

6. Remove cylinder head from engine.

NOTE: It is not necessary to remove turbo, exhaust manifold, water regulator housing, intake manifold, fuel filter base etc. from cylinder head. Remove the oil supply and drain lines from turbo, clamp on bottom of water regulator housing hose, fuel lines, and any other clips or clamps attaching parts between the cylinder head and cylinder block. Remove all bolts attaching cylinder head to cylinder block to remove cylinder head.

7. Remove oil pan.

8. Remove suction screen.

9. Remove piston cooling jets.

10. Remove piston and connecting rod assembly from cylinder liners. It may be necessary to remove built up carbon from the inner diameter of the liner near the top in order to get the piston and connecting rod assembly out of the liner.

11. Remove cylinder liners from cylinder block using 5P-8665 Cylinder Liner Puller.

12. Install 104-3560 Liner Seal on each new 197-9330 Cylinder Liner. Apply 5P-3975 Rubber Lubricant to the liner seal. Install new cylinder liners into cylinder block using 2P-8260 Cylinder Liner Installer.

13. Install new 303-3141 Top Ring, 331-6025 Intermediate Ring, and 265-1113 Oil Ring onto 325-2608 Piston using 4C-3601 Piston Ring Expander. Make sure orientation of piston rings is correct (i.e. rings not installed upside down). Remove piston pin and connecting rod from old piston and install to new piston.

14. Install new 116-1089 Connecting Rod Bearing to connecting rod and connecting rod cap. Install new piston and connecting rod assembly into cylinder liner using 161-4164 Piston Ring Compressor. Make sure the crankshaft throw is at bottom dead center for the respective cylinder being installed. Once the top ring has cleared the cylinder liner, slowly pull connecting rod down to the crankshaft throw making sure that sharp edges of the connecting rod do not damage the crankshaft throw.

15. Install connecting rod cap with new 115-2973 Bolts and tighten to the proper torque specification. Refer to RENR9214 "Piston and Connecting Rods-Install" for proper torque specification and installation instructions.

16. Install piston cooling jets.

17. Install suction screen.

18. Install oil pan using new 217-3673 Seal.

19. Ensure bottom deck of cylinder head is clean before installing cylinder head.

20. Install new 221-9392 Cylinder Head Gasket.

21. Install cylinder head. Use new 242-1811 and 210-4460 Cylinder Head Bolts and 2S-5658 Washers. Tighten cylinder head bolts to specification. Refer to RENR9214 "Cylinder Head-Install" and "Cylinder Head-Install-In chassis" for cylinder head installation instructions which include the proper torque specification.

22. Install new 230-3775 O-ring (top), 230-3728 O-ring (mid), and 9X-7317 O-ring (tip) onto the fuel injectors.

23. Install fuel injectors into cylinder head. Refer to RENR9214 "Electronic Unit Injector-Install" for installation and torque specification.

24. Install rocker arm mechanism to cylinder head. Refer to RENR9214 "Rocker Shaft and Pushrod-Install" for further information.

25. Install valve cover base. Use new seal 5P-5678 or 272-0389. The 5P-5678 Seal is the ribbon style seal used on older machines. The 272-0389 Seal is press in place style seal used on newer machines. Refer to parts manual for correct usage on machine being serviced.

26. Install the valve cover using the new 229-5711 Seal.

27. Re-attach all external lines to cylinder head such as turbo oil feed and drain, water regulator housing, fuel lines, etc.

28. Re-install engine (if removed) and refill all fluids.

29. Run engine and check for leaks. Repair as necessary.