PRODUCT SUPPORT PROGRAM FOR OIL DRILLING REWORK/ENGINE REPLACMENT ON CERTAIN C1.1 INDUSTRIAL ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR OIL DRILLING REWORK/ENGINE REPLACMENT ON CERTAIN C1.1 INDUSTRIAL ENGINES

Usage:

REBE2716-00

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16Nov2007

U-598

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR OIL DRILLING REWORK/ENGINE REPLACMENT ON CERTAIN C1.1 INDUSTRIAL ENGINES
1000		PS42558

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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 "PS42558" 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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TERMINATION DATE

30Nov2009

PROBLEM

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The existing cylinder block can have a defect that reduces oil pressure on certain C1.1 engines. If not rectified engine wear can be accelerated and premature engine failure may occur.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C1.1	G8M04786-04797, 4860-4872, 4874-4887, 4889-4891

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*****Group 2*****
C1.1	G8M05022, 5024-5043, 5045-5053, 5056, 5058-5060, 5063, 5065-5069, 5161-5167, 5169-5170, 5174, 5176-5178, 5184

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*****Group 3*****
C1.1	G8M04981-04982, 4984, 4988, 4991-4992, 4999-5000, 5002, 5009, 5012-5013

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*****Group 4*****
C1.1	G8M04778-04785

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	2465212	ENGINE AR-PRIM
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an inital order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
1	2536081	ENGINE AR-PRIM
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an inital order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 3*****
1	2681384	ENGINE AR-PRIM
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an inital order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 4*****
1	2299738	ENGINE AR-PRIM
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an inital 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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Engines in the Affected Product require inspection and possible replacement. Refer to the 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%
*****Group 1*****
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 10.5-hour job for Group 1
NOTE: The breakdown for the 10.5 hour job is as follows. 0.5 hours will be allowed for investigation of drilling breakthrough. NOTE: If the investigation finds no breakthrough of the drilling then no further time is allowed for this claim. NOTE: If the investigation finds breakthrough on the drilling then an additional 10 hour will be allowed to complete engine replacement.

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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%
*****Group 2*****
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 10.5-hour job for Group 2
NOTE: The breakdown for the 10.5 hour job is as follows. 0.5 hours will be allowed for investigation of drilling breakthrough. NOTE: If the investigation finds no breakthrough of the drilling then no further time is allowed for this claim. NOTE: If the investigation finds breakthrough on the drilling then an additional 10 hour will be allowed to complete engine replacement.

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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%
*****Group 3*****
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 10.5-hour job for Group 3
NOTE: The breakdown for the 10.5 hour job is as follows. 0.5 hours will be allowed for investigation of drilling breakthrough. NOTE: If the investigation finds no breakthrough of the drilling then no further time is allowed for this claim. NOTE: If the investigation finds breakthrough on the drilling then an additional 10 hour will be allowed to complete engine replacement.

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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%
*****Group 4*****
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 10.5-hour job for Group 4
NOTE: The breakdown for the 10.5 hour job is as follows. 0.5 hours will be allowed for investigation of drilling breakthrough. NOTE: If the investigation finds no breakthrough of the drilling then no further time is allowed for this claim. NOTE: If the investigation finds breakthrough on the drilling then an additional 10 hour will be allowed to complete engine replacement.

PARTS DISPOSITION

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

Rework Procedure

Group Number 1

NOTES:
. Before attempting any work on the oil circuit, ensure that the engine is cleaned of any dirt that might contaminate the lubricating system.
. Oil can be hot after running. Care must be taken to ensure hot oil does not come into contact with exposed skin. Allow engine to cool before undertaking any work.
. Clean up any spilt oil before undertaking further work.

COMPONENT REMOVAL & INSPECTION DETAILS

Place a suitable container below the engine / machine in order to catch any oil that may be spilt during disassembly of the engine.

Remove the Oil Pressure Switch and Adaptor from the right hand side of the engines cylinder block (Figure 1.1.1).

NOTE: Clean up any spillage of oil immediately

Image1.1.1

All components that may require disassembly to complete inspection are graphically represented and listed in figure 1.2.1.

Image1.2.1

Using a suitable cleaning swab clean the rear face of the rocker feed oil drilling, removing any oil and contaminants.

NOTE: Fibre swabs not recommendable due to the risk of contamination.

Inspect the rear face of the rocker feed oil drilling for evidence of BREAKTHROUGH into the crankcase cavity. If breakthrough has occurred engine must be replaced.

Figure 1.3.1 shows acceptable drilling

Image1.3.1

Figure 1.4.1 shows unacceptable drilling, with breakthrough into the crankcase cavity.

Image1.4.1

COMPONENT ASSEMBLY

If no breakthrough is evident then engine can be reassembled.

Assemble the Adaptor and Oil Pressure Switch with new sealing washers (Part No. 153-5936) onto the rocker oil feed pipe as shown below (Figure 1.5.1). A sealing washer must be fitted above and below the banjo fitting.

Oil Pressure Switch and Adaptor to be tightened to a torque of 11.5Nm.

Image1.5.1

Group Number 2

NOTES:
. Before attempting any work on the oil circuit, ensure that the engine is cleaned of any dirt that might contaminate the lubricating system.
. Oil can be hot after running. Care must be taken to ensure hot oil does not come into contact with exposed skin. Allow engine to cool before undertaking any work.
. Clean up any spilt oil before undertaking further work.

COMPONENT REMOVAL & INSPECTION DETAILS

Place a suitable container below the engine / machine in order to catch any oil that may be spilt during disassembly of the engine.

Remove the Oil Pressure Switch and Adaptor from the right hand side of the engines cylinder block (Figure 2.1.1).

NOTE: Clean up any spillage of oil immediately

Image2.1.1

All components that may require disassembly to complete inspection are graphically represented and listed in figure 2.2.1.

Image2.2.1

Image2.3.1

Figure 2.4.1 shows unacceptable drilling, with breakthrough into the crankcase cavity.

Image2.4.1

COMPONENT ASSEMBLY

If no breakthrough is evident then engine can be reassembled.

Assemble the Adaptor and Oil Pressure Switch with new sealing washers (Part No. 153-5936) onto the rocker oil feed pipe as shown below (Figure 2.5.1). A sealing washer must be fitted above and below the banjo fitting.

Oil Pressure Switch and Adaptor to be tightened to a torque of 11.5Nm.

Image2.5.1

Group Number 3

NOTES:
. Before attempting any work on the oil circuit, ensure that the engine is cleaned of any dirt that might contaminate the lubricating system.
. Oil can be hot after running. Care must be taken to ensure hot oil does not come into contact with exposed skin. Allow engine to cool before undertaking any work.
. Clean up any spilt oil before undertaking further work.

COMPONENT REMOVAL & INSPECTION DETAILS

Place a suitable container below the engine / machine in order to catch any oil that may be spilt during disassembly of the engine.

Remove the Oil Pressure Switch and Adaptor from the right hand side of the engines cylinder block (Figure 3.1.1).

NOTE: Clean up any spillage of oil immediately

Image3.1.1

All components that may require disassembly to complete inspection are graphically represented and listed in figure 3.2.1.

Image3.2.1

Image3.3.1

Figure 3.4.1 shows unacceptable drilling, with breakthrough into the crankcase cavity.

Image3.4.1

COMPONENT ASSEMBLY

If no breakthrough is evident then engine can be reassembled.

Assemble the Adaptor and Oil Pressure Switch with new sealing washers (Part No. 153-5936) onto the rocker oil feed pipe as shown below (Figure 3.5.1). A sealing washer must be fitted above and below the banjo fitting.

Oil Pressure Switch and Adaptor to be tightened to a torque of 11.5Nm.

Image3.5.1

Group Number 4

NOTES:
. Before attempting any work on the oil circuit, ensure that the engine is cleaned of any dirt that might contaminate the lubricating system.
. Oil can be hot after running. Care must be taken to ensure hot oil does not come into contact with exposed skin. Allow engine to cool before undertaking any work.
. Clean up any spilt oil before undertaking further work.

COMPONENT REMOVAL & INSPECTION DETAILS

Place a suitable container below the engine / machine in order to catch any oil that may be spilt during disassembly of the engine.

Remove the Oil Pressure Switch and Adaptor from the right hand side of the engines cylinder block (Figure 4.1.1).

NOTE: Clean up any spillage of oil immediately

Image4.1.1

All components that may require disassembly to complete inspection are graphically represented and listed in figure 4.2.1.

Image4.2.1

Image4.3.1

Figure 4.4.1 shows unacceptable drilling, with breakthrough into the crankcase cavity.

Image4.4.1

COMPONENT ASSEMBLY

If no breakthrough is evident then engine can be reassembled.

Assemble the Adaptor and Oil Pressure Switch with new sealing washers (Part No. 153-5936) onto the rocker oil feed pipe as shown below (Figure 4.5.1). A sealing washer must be fitted above and below the banjo fitting.

Oil Pressure Switch and Adaptor to be tightened to a torque of 11.5Nm.