PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY CLEANING 10R-5457 CONNECTING RODS IN CERTAIN CYLINDER PACKS, SHORT BLOCKS, AND LONG BLOCKS IN DEALER PARTS STOCK Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY CLEANING 10R-5457 CONNECTING RODS IN CERTAIN CYLINDER PACKS, SHORT BLOCKS, AND LONG BLOCKS IN DEALER PARTS STOCK

Usage:

REBE8967-01

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09Oct2012

(Revised 09Oct2012)

U-532

A-421

D-454

O-488

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*Parts stock action only*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY CLEANING 10R-5457 CONNECTING RODS IN CERTAIN CYLINDER PACKS, SHORT BLOCKS, AND LONG BLOCKS IN DEALER PARTS STOCK
1218 1225		PI70459

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NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the 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 09Oct2012 Service Letter. A change has been made to the Title.

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TERMINATION DATE

31Jan2013

PROBLEM

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Some C27 and C32 cylinder packs, short blocks, and long blocks with certain part numbers, packaged between September 1, 2011 and December 31, 2011, may contain 10R-5457 Connecting Rods that have debris in the oil passage to the pin bore. This debris may cause early hour failure to the bearings.

ACTION REQUIRED

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Inspect the part numbers that are listed in Image 1 in dealer parts stock.

Inspect the part numbers in Image 1 for the affected packaging date code in the date code range of "D01M09Y11P68HL" through "D31M12Y11P68HL". Refer to Image 2.

If a cylinder pack is found with affected packaging date code, open the top of the box and inspect the connecting rod cap. If "10R-5457 NDUU" or "10R-5457 UNUU" is etched on the rod cap, then the cylinder pack must be further inspected for debris as described below. Refer to Image 3. If the rod cap does not have the suspect part number (in the case of a new rod substitution) or the rod cap has a different 4-letter date code, then the connecting rod is acceptable for use.

If a short block is found with affected packaging date code, block must be removed from crate and packaging, and safely lifted to allow viewing rod caps. Inspect each connecting rod cap. If the Connecting Rod has "NDUU" or "UNUU" etched on the connecting rod cap, then further inspection for debris is required as described below. If the rod cap does not have the suspect part number or the rod cap has a different 4-letter date code, then the connecting rod is acceptable for use.

If a Long Block is found with affected package date code, contact Reman Product Support Engineer Robert Cannon at cannon_robert_k@cat.com for further instruction. It is not anticipated that any affected Long Block part numbers will be in dealer parts stock.

CONNECTING ROD OIL PASSAGE INSPECTION AND CLEANING

Connecting rods within the affected date code range can be inspected using a borescope with a 4.7 mm (0.2 inch) lens or any comparable borescope that fits through the 6 mm (0.24 inch) oil passage. Image 4 and Image 5 show a cylinder pack rod being inspected without removing rod cap. If no debris is present through oil passage as in Image 6, the cylinder pack is acceptable. An affected connecting rod with debris as shown in Image 7.

CYLINDER PACK ROD CLEANING

Individual cylinder packs with debris in rods should be cleaned as follows.

1. Carefully pull out the piston from the cylinder until the piston pin is exposed but rings are still within the bore.

2. Remove one snap ring. Note the orientation of gap.

3. Remove the pin and rod.

4. Remove the rod cap.

5. Use pipe cleaner or wire and cloth to push through hole and remove debris. Repeat until clean.

6. Clean the rod bearing and surfaces of any debris.

7. Apply clean engine oil to the pin and small end bearing.

8. Install the pin, rod, and snap ring in same orientation as removed.

9. Install the rod cap.

10. Push the piston back down.

11. Reseal the packaging and close the box.

SHORT BLOCK ROD CLEANING

1. Lift the block from the crate and remove the packaging over bottom of block in a clean environment.

2. Connecting rods with the affected date codes "NDUU" or "UNUU" need the crankshaft rotated until the piston is near the bottom of the cylinder to allow rod cap removal.

3. Remove rod cap and carefully push piston until rod oil hole is accessible.

4. Inspect oil passage with borescope. If no debris is present as in Image 6, the rod is acceptable. An affected connecting rod with debris (4) can be seen in Image 7.

5. If debris is found, remove piston and rod from engine, noting orientation of piston in block.

6. Remove one piston pin snap ring, noting orientation of gap.

7. Remove pin and rod.

8. Use pipe cleaner or wire and cloth to push through hole and remove debris. Repeat until clean.

9. Clean rod bearings and surfaces of any debris.

10. Apply clean engine oil to bearing surfaces.

11. Install pin, rod and snap ring in same orientation as removed.

12. Install piston, rod and rod cap per KENR8167 or equivalent. Existing bolts can be reused.

13. Repeat for each affected rod.

14. Repackage block and return to crate.

Return the affected parts to dealer parts stock after completion.

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SERVICE CLAIM ALLOWANCES

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Submit one claim for all parts inspected and possibly cleaned in dealer parts stock. For cylinder packs, 0.25 hour is allowed for each affected rod that is inspected with a borescope and possibly cleaned. For short blocks, 1 hour is allowed for inspection/rework setup plus 0.5 hour for each affected rod that is inspected with a borescope and possibly cleaned.