PRODUCT IMPROVEMENT PROGRAM FOR SAMPLING THE ENGINE OIL AND IF NECESSARY REPLACING THE IDLER GEAR ASSEMBLY ON 3054C ENGINES INSTALLED IN CERTAIN ASV RC85 AND RC100 MACHINES Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR SAMPLING THE ENGINE OIL AND IF NECESSARY REPLACING THE IDLER GEAR ASSEMBLY ON 3054C ENGINES INSTALLED IN CERTAIN ASV RC85 AND RC100 MACHINES

Usage:

SEBE8999

December 1, 2004
U-350
D-271


 
Priority 

Parts stock action needed

PRODUCT IMPROVEMENT PROGRAM FOR SAMPLING THE ENGINE OIL AND IF NECESSARY REPLACING THE IDLER GEAR ASSEMBLY ON 3054C ENGINES INSTALLED IN CERTAIN ASV RC85 AND RC100 MACHINES

1234, 5073, 1387, 7542
PI30743
NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30743" 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 "PI30743" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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.

NOTE: Make every effort to administer this program in a timely manner, but with the least incursion into the customers? operation. Taking oil samples at the normal maintenance interval, especially where Customer Support Agreements are in existence, or where customers already use Scheduled Oil Sampling, is advised to keep program costs to a minimum. This program also affords an opportunity to promote CSAs and SOS with customers not currently enrolled.

COMPLETION DATE

TERMINATION DATE

June 30, 2005 December 31, 2005

PROBLEM

There have been reports of premature wear on the idler gear bushing assembly and idler hub.
Root cause has been identified as a machining process change made by the gear supplier, which had an undesirable effect on the surface finish of some idler gear bushings. Copper content in the oil has been identified as an accurate method for predicting whether the engine will be affected by the accelerated wear condition.
Rework of the idler gear assembly is recommended if the copper content in the oil exceeds the threshold levels detailed below

(expressed as Cu).

NOTE: Oil samples should be taken during routine service intervals (unless an oil sampling program is already in existence with predetermined intervals which are more frequent than the normal service intervals).

While elevated copper levels from SOS sampling can effectively identify accelerated idler gear bearing wear, occasional hard cold starting difficulties may also indicate premature idler gear bearing wear.

AFFECTED PRODUCT

NOTE: The affected serial number list shown below excludes machines that were repaired under an earlier field probe to determine the extent of this problem. Other machines may already have been repaired with parts announced in TIBU4161. While these machines may still be included in the list below, there is no need to replace the idler gear assembly again.

NOTE: If your machine is in the affected product below and is a new machine being currently held in Dealer stock or inventory, apply this PI and re-work the Idler gear As. (There is no requirement to sample the oil).

Model Identification Number
3054C 334382-410, 412, 414-430, 436-443, 460-467, 477-486, 490-496, 522-544, 546-548, 550-554, 572-581, 583-584, 586-604, 670-675, 677-700, 710, 754-764, 766-786, 799-831, 835, 1177-1183, 1185-1200, 1202-1206, 1208-1220, 1262, 1277, 1325-1330, 1332-1342, 1344, 1346-1357, 1372, 1376-1379, 1388-1391, 1393-1416, 1428-1438, 1440-1467, 1469-1503, 1505-1559, 1565-1568, 1570-1573, 1575-1599

PARTS NEEDED

Qty

Part Number Description
1 OIL SAMPLING KIT
1 2258019 GASKET-PUMP
1 2258287 GASKET-COVER
1 2514336 GEAR AS-IDLE
1 2546029 HUB-IDLER GEAR
1 2551209 PLATE-RETAIN
3 6I-0650 BOLT

ACTION REQUIRED

***** Parts Stock *****

Remove all 232-3668 parts from parts stock.

***** Affected Product *****

An oil sample must be taken from all engines in the affected product range. The oil sample report must be attached to all claims that include an idler gear change. Make every effort to administer this program in a timely manner, but with the least incursion into the customers? operation. Taking oil samples at the normal maintenance interval, especially where Customer Support Agreements are in existence, or where customers already use Scheduled Oil Sampling, is advised to keep program costs to a minimum. This program also affords an opportunity to promote CSA?s and SOS with customers not currently enrolled.

NOTE: The copper level in the oil sample analysis will determine whether or not any further action is necessary. Make every effort to take the oil sample concurrent with the normal oil change interval for the engine. Use the following information and flow chart as a guide to whether or not further action is required. Oil sample results from 1st service interval (no longer than 500 hours of engine service):

Cu 0 - 50-ppm Change oil & recheck at 2nd service (no longer than 1000 hours of engine service)

Cu 51 - 100 ppm Change oil & resample after a further 250hrs

Cu > 101 ppm Rework idler gear assembly

Oil sample results at 2nd check (750 hrs)

Cu 0 - 50 ppm No action required

Cu > 51 ppm Rework idler gear assembly

Oil sample results from 2nd service

Cu 0 - 50 ppm No action required

Cu > 51 ppm Rework idler gear assembly

If no evidence of elevated copper levels have been found in the oil samples after 1000 hours of service (above 50 ppm over 2 service intervals), the engine should be considered unaffected by this issue and no further testing or action is required.

The following process flow explains the policy and actions required.
 

The results of the oil sample are the most accurate method of determining whether or not the idler gear bearing has worn, or will wear prematurely. Copper level in early oil samples may be artificially elevated due to engine break in. Keep in mind the other factors used to determine an idler gear bearing problem:
  • Hard starting
  • Engine miss or stutter

OWNER NOTIFICATION

U.S. and Canadian owners will NOT receive an Owner Notification.

SERVICE CLAIM ALLOWANCES

***** Parts Stock *****

Submit one claim for all 232-3668 parts removed from parts stock.

***** Affected Product *****


 
Product smu/ 
Caterpillar
Dealer Suggested
Customer Suggested
Parts
Labor Hrs
Parts
Labor Hrs
Parts
Labor Hrs
0 ? 3000
0 ? 36 mo.
100%
1.0*
0
0
0
0
0 ? 3000
0 ? 36 mo.
100%
4.5**
0
0
0
0
NOTE: * The 1.0 hour of labor is for administrative duties involved in mailing out the sample bottle, and processing the returned sample. NOTE: **Up to 4.5 labor hours will be allowed to replace the idler gear assembly and associated parts if, and only if, the oil sample result shows excessive copper.

PARTS DISPOSITION

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

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

Rework Procedure
Note: This procedure is for engines fitted with DP-210 Fuel Injection Pumps. This process can be also be used on engines fitted with the Bosch EVPE Mechanical FIP, however one needs to put a spanner on the FIP shaft nut to hold it against the springs in the FIP. It can also be used with a LHS PTO fitted without needing the removal of the PTO.
 
 
Preparatory Strip-down
 
 
  1. Remove alternator adjusting link and belts if fitted.
  2. Remove water pump and joint, not removing the 2 bottom-left screws which retain the water pump the cover, as shown:

  3. Remove timing case cover
  4. Remove injector cover to gain access to glow plugs
  5. Remove glow plugs to enable the engine to be turned

  6.  
  7. Turn the engine in direction of rotation to enable the crankshaft and camshaft locating pins to be fitted. Insert 230-6283 Crankshaft timing pin through the housing (front) and into the web of the crankshaft. Insert the 230-6284 Camshaft timing pin through the camshaft gear and into the housing (front).


Idler Gear Removal

  1. Remove the three idler fixing screws (6) and the thrust plate (7).

  2. Note the single mark on the FIP gear may not be aligned with the two marks on the idler gear. The idler gear marks ?walk? and several more rotations would be required to align the marks. This does not matter.

  3. DO NOT remove the FIP gear and do not lock the FIP.
     

  4. Remove the camshaft timing pin, leave the crankshaft locating pin in place. Remove the Camshaft gear fixing bolt (1) and remove the camshaft gear (2). Dependant on the ?fit? this may need a puller.

  5. Now withdraw the idler hub and gear. Note: To remove the idler hub and gear insert three M10 screws back in the idler hub after removal of the plate, but make no attempt to screw the fixing into the thread. Now grab the three fixings and squeeze so that they lock into the hub, then move them about and pull to disengage the spigot from the cylinder block. Angle the hub and gear so that you can draw it out. Remember that because of the helix and the locked crank gear any other gear must be free to rotate as the teeth are disengaged.

  6. Ensure all mating surfaces are clean, Re-assemble Gear Train

  7.  
  8. Turn the FIP gear so that the single mark is pointing at the crankshaft.

  9.  
  10. Fit the new idler hub and gear (lubricating with clean engine oil) so that the pair of marks on the idler enclose the single mark on the FIP gear. This may need more than one attempt since the correct crank gear tooth must be meshed with the idler to bring the marks in line with the gear centre-line.
  11. Fit the new thrust plate and screws and torque to 44Nm. Check that there is end float and backlash.

  12.  
  13. Refit the camshaft gear. This is located on the camshaft by the key-way and the helix means that the camshaft must rotate slightly as the gear is pushed home. The gear must fit so that the marks and locating pin all align / fit. If the idler has been fitted on the wrong crankshaft tooth this will not be the case. Check for backlash.

  14.  
  15. Refit the camshaft gear fixing bolt and washer. Tighten to 95Nm but do not use the locating pin to prevent the engine from turning.

  16.  
  17. Remove the pins and rotate the crankshaft circa 90 degrees anticlockwise. Rotate it clockwise towards TDC until the crankshaft locating pin can be fitted. Check that the timing marks all align and the camshaft locating pin will fit.

  18.  
  19. Rebuild to running condition using new gaskets.
Other Torque Settings;

Timing Case cover and water pump screws 22Nm.

Glow plugs 15Nm.

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