2009/08/03 Caterpillar

Industrial Engine:

C2.2 (S/N: C4M1-241,244-319,321-323,325-417,419-580,582-697,699-702,704-813,815-837,839-862,888-889,934-1019,1028-1068,1070-1074,1077-1125,1128-1143,1146-1149,1151-1152,1158-1171,1173-1182,1184-1293,1295-1303,1305-1336,1338-1505,1508-1551,1556-1561,1563-1576,1578-1598,1603-1641,1644-1644,1647-1830,1837-1856,1858-1930,1932-1941,1943-1962,1964-1964,1966-1984,1986-2103,2105-2117,2120-2129,2131-2268,2270-2336,2338-2400,2403-2403,2405-2418,2420-2463,2465-2474,2476-2628,2630-2630,2632-2689,2691-2739,2741-2778,2780-2820,2822-2832,2834-3055,3057-3200,3202-3206,3209-3269,3275-3275,3277-3277,3279-3279,3282-3284,3296-3296,3299-3299,3301-3301,3305-3305,3895-3895; C6M1-202,204-204,206-212,217-218,221-223,225-228,230-259,261-264,266-325,327-468,470-1124,1126-1128,1130-1130,1135-1187,1189-1328,1330-1330,1333-1348,1350-1360,1363-1364,1367-1368,1370-1404,1406-1418,1420-1433,1437-1454,1456-1523,1525-1530,1542-1542,1544-1544,1556-1558,1572-1575,1591-1600,1602-1639,1641-1645,1647-1663,1665-1673,1675-1676,1678-1680,1682-1727,1729-1730,1733-1735,1737-1738,1741-1741,1745-1745,1749-1753,1759-1770,1772-1773,1775-1780,1782-1807,1810-1812,1815-1815,1818-1819,1821-1833,1835-1879,1881-1882,1884-2008,2010-2014,2016-2016,2018-2024,2026-2039,2041-2144,2146-2191,2194-2201,2203-2215,2218-2218,2224-2227,2236-2236,2258-2260,2293-2295,2300-2303,2319-2327,2332-2335,2352-2352; G7M1-244,246-246,248-252,254-255,257-274,276-336,339-355,358-399,401-408,410-462,464-521,523-536,538-566,568-590,592-597,599-642,644-649,652-665,668-668,670-677,679-680,682-691,693-701,703-727,729-805,807-830,832-876,878-908,910-913,915-930,932-936,938-1011,1013-1026,1028-1039,1041-1041,1043-1062,1064-1107,1109-1136,1138-1165,1167-1197,1199-1200,1204-1205,1208-1221,1223-1397,1399-1456,1458-1583,1585-1616,1618-1648,1650-1662,1664-1676,1678-1766,1768-1778,1780-1784,1786-1829,1831-2006,2008-2029,2031-2037,2039-2145,2147-2147,2151-2151,2153-2222,2224-2275,2277-2287,2289-2313,2315-2318,2320-2322,2324-2406,2408-2409,2411-2418,2420-2461,2463-2476,2478-2515,2517-2602,2604-2619,2621-2628,2630-2770,2772-2772,2774-2802,2804-2812,2814-2883,2885-2921,2923-3038,3040-3049,3051-3074,3076-3101,3103-3121,3123-3137,3139-3204,3206-3234,3236-3245,3247-3257,3259-3268,3270-3339,3341-3363,3366-3409,3411-3435,3437-3445,3447-3522,3524-3526,3528-3550,3552-3579,3581-3659,3661-3725,3727-3728,3730-3757,3759-3772,3774-3831,3834-3928,3930-3965,3967-3969,3971-3980,3983-4047,4049-4062,4064-4137,4139-4347,4349-4375,4377-4523,4525-4589,4591-4611,4613-4774,4777-4779,4786-4786,4788-4788,4790-4972,4974-4975,4977-4978,4980-5187,5189-5203,5205-5205,5207-5265,5267-5418,5420-5431,5433-5436,5438-5465,5468-5541,5543-5544,5546-5582,5584-5778,5780-5821,5823-5902,5904-5970,5972-5987,5989-6187,6189-6206,6208-6209,6212-6214,6216-6473,6475-6479,6481-6485,6487-6487,6489-6491,6493-6502,6504-7061,7064-7286,7288-7346,7348-7689,7691-7730,7732-7844,7857-7884,7887-8124,8126-8194,8196-8287,8289-8371,8373-8466,8468-8528,8530-8530,8532-8618,8621-8648,8650-8670,8672-8722,8724-8724,8726-8726,8728-8728,8731-8872,8874-8930,8932-9126,9128-9166,9170-9170,9172-9234,9236-9309,9312-9412,9414-9750,9752-9757,9759-10211,10213-10213,10217-10218,10222-10222,10227-10227,10231-10232,10240-10241,10243-10243,10246-10246,10248-10249,10252-10252,10255-10255,10257-10257,10260-10260)

3024C (S/N: G4P475-475,912-912,928-928,1033-1051,1082-1105,1188-1188,1248-1248,1307-1316,1383-1392,1444-1444,1454-1454,1464-1464,1472-1472,1486-1486,1488-1488,1525-1526,1528-1539,1558-1558,1560-1569,1571-1578,1583-1584,1586-1600,1614-1679,1698-1867,1869-1869,1913-1920,1926-1992,1994-2032,2034-2127,2129-2132,2137-2211,2213-2241,2243-2248,2318-2331,2333-2334,2336-2344,2346-2387,2393-2464,2466-2474,2480-2516,2518-2520,2539-2557,2581-2586,2593-2632,2634-2754,2756-2761,2763-2773,2775-2815,2819-2861,2863-2874,2908-2925,2927-2928,2930-2972,2974-2976,2978-2978,2980-2989,2991-3010,3012-3018,3021-3029,3035-3043,3045-3048,3050-3053,3055-3083,3085-3086,3088-3089,3091-3132,3134-3142,3144-3337,3339-3384,3386-3607,3609-3618,3620-3794,3796-3938,3940-3941,3943-3979,3981-4003,4005-4028,4030-4109,4111-4408,4410-4429,4431-4475,4477-4509,4511-4605,4607-4650,4652-4715,4717-4717,4719-4729,4731-4753,4755-4790,4792-4802,4804-4821,4823-4823,4825-4913,4915-4939,4941-5027,5029-5069,5072-5165,5167-5172; 4241251-1253,7003-7003,9761-9770,9958-9991,10012-10031,10391-10465,10467-10570,10573-10674,10676-10772,10774-10951,10953-10963,10965-11010,11014-11040,11042-11344,11346-11395)

Generator Set:

C2.2 (S/N: NCB1-407,409-443,446-455,457-473,477-492,495-503,505-600; XYE1-397,404-445,448-475,478-480,482-503,508-549,551-560,590-598,600-600,602-607,611-668,670-682; TAG1-1,271-272,428-430,462-487,489-489,491-600,602-933,938-938; JAW1-1,151-176,178-322,324-324)

There have been a number of isolated instances of issues with 217-1456 Piston Ring Kit, 270-6968 Piston, 297-3080 Piston and 270-6970 Piston Ring Kit on 3024C and C2.2 engines.

The issues include the following components.

• Seized pistons

• Broken piston rings

• Scratched cylinder bores

• Piston rings that are incorrectly installed, incorrect installation of piston rings may be due to the piston ring gaps that are not in the correct position or the piston rings that are upside-down.

• Piston rings not seated correctly.

Reports suggest multiple root causes of the issues.

Excessive low speed or running the engine with a low load for extended periods can lead to excessive oil consumption and carbon buildup on the top of the piston, piston rings and the piston grooves. This can lead to excessive wear and damage to components.

Incorrect maintenance of air cleaner leads to dust, that causes excessive wear of pistons, piston rings and cylinder bores.

Defects from the assembly process can lead to the following issues.

• Piston rings that are installed upside-down

• Piston ring gaps that are not in the correct position

• Incorrect piston rings that are installed

Note: Piston rings can turn in the groove in the piston during normal operation of the engine.

Overheating of the engine can lead to damage of the piston skirts, rings and cylinder bores. This can be due to low coolant levels,thermal cycling or loss of coolant system pressure.

Issues with the gasket for the cylinder head have resulted in issues with the engine. This includes the following issues.

• Oil contamination with carbon

• Starvation problems with oil

• Engine overheating

All of these issues can lead to damage to the piston and the piston ring.

Refer to the Operation and Maintenance Manual for the correct procedures in order to start an engine and engine operation.

Refer to the Operation and Maintenance Manual for information on maintenance and cleaning of the air cleaner. This will prevent dust in the engine.

The assembly process has been improved. This includes addressing the following potential issues.

• Incorrect piston rings that are installed

• Piston ring gaps that are not in the correct position

• Piston rings that are installed upside-down

For the correct procedure to assemble the piston and piston rings, refer to Disassembly and Assembly, "Pistons and Connecting Rods - Assemble".

There have been multiple improvements that have been made to the engine. These improvements will affect the piston and the piston rings. These improvements include the following components.

• The introduction of a water pump with the high flow bypass and the water temperature regulator housing. This reduces the severity of thermal cycling. This will reduce the chances of the engine overheating.

• A new cylinder head gasket has been introduced. This will resolve instances of excessive oil consumption and carbon buildup. This leads to damage to the piston and the piston ring, engine overheating and issues with excessive smoke or low power.

• A new oil pump has been introduced. This will increase the oil flow. The new engine oil pump will reduce the wear of the engine components.