PRODUCT SUPPORT PROGRAM FOR REWORKING ENGINE LOW IDLE SPEED ON CERTAIN 306E AND 307E MINI HYDRAULIC EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING ENGINE LOW IDLE SPEED ON CERTAIN 306E AND 307E MINI HYDRAULIC EXCAVATORS

Usage:

TEBE0366-01

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08Feb2014

(Revised 20Feb2014)

D-59

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING ENGINE LOW IDLE SPEED ON CERTAIN 306E AND 307E MINI HYDRAULIC EXCAVATORS
1000 1264 1908		PS44178

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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 "PS44178" 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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NOTE:	This Revised Service Letter replaces the 08Feb2014 Service Letter. Changes have been made to wording in the Rework Procedure.

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TERMINATION DATE

28Feb2015

PROBLEM

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The existing low idle engine speed may causes rigid swing movement on certain 306E and 307E Mini Hydraulic Excavators.

AFFECTED PRODUCT

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Model	Identification Number
306E	FHL00107-00242
307E	H1Y00100-00308, 310-387, 400, 403-404, 406-410, 453-454, 513-518

PARTS NEEDED

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Qty	Part Number	Description
1	4502224	WIRE
1	4502225	RETAINER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 10% 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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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%
0-2500 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-hour job

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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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Note: Both 306E and 307E Mini Hydraulic Excavator engines will be covered in this Service Letter.

Refer to Image1.1.1 for the detailed affected machine serial number and the rework requirements.

Image1.1.1

1. Park the machine on level ground with the implements lowered. Refer to Image1.2.1.

Refer to RENR9744, Disassembly and Assembly, "System Pressure - Release", in order to prepare the machine for this Rework Procedure.

Image1.2.1

2. Ensure the ignition key is in OFF position and isolator key is turned OFF.

3. Clean a small area of the front crankshaft pulley surface (A) with a clean cloth. Refer to Image1.3.1.

4. Cut and paste reflective tape onto surface (A) for engine rpm recording later in this Rework Procedure. Refer to Image1.3.1.

Image1.3.1

5. Cut and break the engine low idle adjustment setscrew tamperproof seal (B). Refer to Image1.4.1.

Image1.4.1

For 307E Machine:

1. Turn ON battery isolator key.

2. Turn ON the machine ignition key and ensure power mode and air-conditioning switches are in the OFF position. Refer to Image1.5.1.

Image1.5.1

For 306E Machine:

1. Turn ON battery isolator key.

2. Turn ON the machine ignition key and ensure power mode and air-conditioning switches are in the OFF position. Refer to Image1.6.1.

Image1.6.1

3. Run the engine at low idle speed for one minute.

4. Increase the speed throttle and measure the engine speed using a tachometer aiming at the reflective tape that was pasted earlier in this Rework Procedure. Refer to Image1.7.1.

5. Ensure that the engine is increased to approximately 1600?1800 rpm for two minutes by adjusting the speed throttle.

6. Then, increase the speed throttle to maximum position and run for another one minute.

7. After the engine has been warmed up, decrease speed throttle to the minimum position and record the engine low idle rpm using the tachometer. (Example: Low idle speed measured estimated is at 950 rpm).

8. If the measured low idle speed is at 1080?1100 rpm, proceed to section "Tamper Proof Re-Sealing Steps", and perform the tamper proof resealing of the low idle adjustment setscrew.

9. If the measured low idle speed is NOT at 1080?1100 rpm, continue the next step.

Image1.7.1

10. Loosen the locknut and turn in slowly the low idle speed adjustment setscrew to increase another 100 rpm. Refer to Image1.8.1.

11. Confirm and record the engine low idle speed using the tachometer. (Estimated at 1080 to 1100 rpm).

Image1.8.1

12. Manually pull and release the engine throttle lever (C) a few times in order to rev-up the engine. Refer to Image1.9.1.

13. Measure the engine low idle speed using tachometer again to ensure that the low idle speed has been increased by 100 rpm correctly.

14. Tighten back the locknut.

15. Repeat the above step for re-adjustment, if necessary.

Image1.9.1

Tamper Proof Re-Sealing Steps:

1. Insert one end of the wire through low idle adjustment screw (D) bolt hole with an
extension of distance C: 40mm. Refer to Image1.10.1.

Image1.10.1

2. Using the other end of the wire, wire a full completed round over low idle adjustment screw (D). Refer to Image1.11.1.

Image1.11.1

3. Continue to insert the other end of the wire into high idle adjustment screw (E). Refer to Image1.12.1.

Image1.12.1

4. Wire the other end of the wire with a full completed round over the high idle adjustment screw (E). Refer to Image1.13.1.

Image1.13.1

5. Re-wire the other end of the wire back to and over low idle adjustment screw (D). Refer to Image1.14.1.

Image1.14.1

6. Bundle and twist the other end of the wire together with the extension wire (C) using a six inch plier for a length of 15mm. Refer to Image1.15.1.

Image1.15.1

7. Insert the seal into bundled wire. Refer to Image1.16.1.

Image1.16.1

8. Using pliers, clamp and squeeze hard the seal with the inserted bundle wire. Ensure that the seal and the bundled wire do not come loose. Refer to Image1.17.1.