Product Support Program For Cylinder Block Liner Seat Cracking On Certain D11N, D11R, 776B, 776C And 776D Tractors, 777B, 777C, 777D, 784B, 785, 785B, 789, 789B, 793, 793B And 793C Trucks, 992G And 994 Wheel Loaders, And 5130 AND 5230 Excavators Caterpillar

Product Support Program For Cylinder Block Liner Seat Cracking On Certain D11N, D11R, 776B, 776C And 776D Tractors, 777B, 777C, 777D, 784B, 785, 785B, 789, 789B, 793, 793B And 793C Trucks, 992G And 994 Wheel Loaders, And 5130 AND 5230 Excavators

Usage:

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Caterpillar: Confidential Yellow

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: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0480" as the Part Number and "7755" as the Group Number. Use "96" as the WarrantyClaim Description Code and use "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the October 26, 1990 Service Letter (Revised June 1995). Changes have been made to the Termination Date, Problem Description and Affected Product.

Termination Date

December 31, 1997

Problem

At overhaul, the engine cylinder block may have cracks on the top deck of the cylinder block under the cylinder liner flange on some C Trucks, and Excavators.See Rework Procedures A and B.

Some cylinder blocks that were repaired using the previously available 7E2866 Inserts may develop coolant leaks externally at the cylinder head gasket joint or internally into the lubrication system prior to overhaul. See Rework Procedures C and D.

Affected Product
Model & Identification Number

D11N (74Z1-1152, 4HK1-635)

D11R (8ZR1-Up)

776B (6JC1-108)

776C (2TK1-114)

776D (5ER1-Up)

777B (4YC1-1866, 3NF1-69)

777C (4XJ1-1123)

777D (3PR1-Up)

784B (5RK1-UP)

785 (8GB1-697)

785B (6HK1-Up)

789 (9ZC1-699)

789B (7EK1-Up)

793 (3SJ1-56)

793B (1HL1-524)

793C (4AR1-Up)

992G (7HR1-Up)

994 (9YF1-Up)

5130 (5ZL1-Up)

5230 (7LL1-Up)

Parts Needed

Rework Procedure A

1 -7W5949 Liner Seat Insert (3.20 mm. (.125 inch))

1 - 1204334 Liner Seat Insert (5.08 mm. (.200 inch))

1 - 1204337 Liner Seat Insert (7.62 mm. (.300 inch))

NOTE: Use one insert per cylinder.

Rework Procedures B, C or D

4 - 1B4367 Bolt

2 - 8S2332 Bolt

2 - 1011368 Thrust Washer

2 - 1121552 Idler Shaft

2 - 1121554 Idler Gear Assembly

1 - 1153503 Cylinder Block (for 3508 Engines)

1 - 1155154 Cylinder Block (for 3512 Engines)

1 - 1155160 Cylinder Block (for 3516 Engines)

10 - 1161359 Camshaft Bearing (for 3508, 14 for 3512, and 18 for 3516 Engines)

Action Required

Rework Procedure A, B, C or D are only to be used as follows:

Procedure A - Use Procedure A if a cylinder(s) of a product was not previously repaired for top deck cracks and cracks are now found during an overhaul.

Procedure B - Use Procedure B after inspecting the top deck of the cylinder block at overhaul to determine the location of the cracks, and finding cracks extending into a bolt hole or water passage.

Procedure C - Use Procedure C if the product was previously repaired for top deck cracks using the 7E2866 Insert and a repair is now necessary prior to overhaul due to external coolant leaks at the cylinder head gasket joint or internal leaks into the lubrication system.

Procedure D - Use Procedure D if the product was previously repaired for top deck cracks using the 7E2866 Insert and the engine is again being overhauled.

For details of the actual reworks, refer to the attached rework procedures.

Service Claim Allowances

NOTE: As "Product" actually applies to the cylinder block rather that the engine, the claim comments MUST clearly state:

1. Which overhaul for the cylinder block

and

2. Which procedure was used

Repair Procedure A

NOTE: For Procedures B, C and D, whenever a cylinder block is replace, record the cylinder block sequence number (located on to of the cylinder block in front of the number 1 cylinder) in the history folder.

Repair Procedure B

Repair Procedure C

Repair Procedure D

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

Rework Procedure A

NOTE: While the complete removal of a crack is the most positive repair, over five years of testing and field experience has proven that the replacement of a cylinder block just because a crack exists beyond 7.62 mm. (.300 inch) is not necessary. Whether using one of the three Caterpillar inserts or an outside supplied insert of the recommended material, whether the cracks are completely removed or not, Caterpillar considers this to be a positive, life-long repair. Further, to avoid a continuing need to insert different cylinders at each overhaul, Caterpillar recommends inserting all cylinders at the same time.

1. If using one of the three inserts listed under Parts Needed, refer to the Reuse and Salvage Guideline, SEBF8255, Procedure to Counterbore Top Deck of Cylinder Block and Install Liner Insert for the installation specifications and instructions.

2. If using other than a Caterpillar insert, the recommended insert material is a 40,000 psi tensile strength gray iron (ASTM A48 Grade 40B) or a ductile iron (ASTM A536 Grade 65-45-12). Refer to the above mentioned guideline, SEBF8255, for cylinder block machining instructions.

3. Make and insert with an outside diameter (OD) that will provide an interference fit between the insert and the cylinder block of between 0.015 and 0.025 mm (.0006 and .0010 inch) for each inch of insert diameter. The insert OD must have a lead-in chamfer of 0.90 ± 0.13 mm (.035 ± .005 inch) by 30 degrees.

4. Apply 4C9507 Retaining Compound to the OD of the insert only. Press the insert into place in the cylinder block counterbore. Maintain the press for a minimum of 15 minutes to one hour.

NOTE: The retaining compound requires 15 minutes to one hour to cure.

5. Resurface the head face of the cylinder block not exceed a flatness of 0.05 mm (.002 inches) per cylinder head abutment area and not to exceed a surface finish of 120 micro inches.

Rework Procedure B

During the inspection of the top deck of the cylinder block at overhaul, if cracks are found extending into a bolt hole or water passage, replace the cylinder block.

Rework Procedure C

Remove the engine and replace the cylinder block.

NOTE: Caterpillar does not recommend the reuse of cylinder blocks with 7E2866 Inserts. Use of the new 1106993 Liner in cylinder blocks with the 7E2866 Insert may result in the failure of the cylinder liner flange.

Rework Procedure D

Remove the engine and replace the cylinder block.

NOTE: Caterpillar does not recommend the reuse of cylinder blocks with 7E2866 Inserts.Use of the new 1106993 Liner in cylinder blocks with the 7E2866 Insert may result in the failure of the cylinder liner flange.