PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING 10R8154, 10R8155, 10R8156, AND 10R8157 REMAN CYLINDER PACKS IN DEALER PARTS STOCK Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING 10R8154, 10R8155, 10R8156, AND 10R8157 REMAN CYLINDER PACKS IN DEALER PARTS STOCK

Usage:

REBE6777-00

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04Jan2011

U-7

A-6

D-7

O-6

TT-2

TM-1

TA-1

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*Parts stock action only*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING 10R8154, 10R8155, 10R8156, AND 10R8157 REMAN CYLINDER PACKS IN DEALER PARTS STOCK
7750		PI70375

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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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TERMINATION DATE

30Apr2011

PROBLEM

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Certain 10R8154, 10R8155, 10R8156, and 10R8157 Reman cylinder packs with the date code ranges beginning July 1, 2010 through November 4, 2010, were assembled incorrectly. A failure to the engine will result if these cylinder packs are installed.

ACTION REQUIRED

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Inspect all 10R8154, 10R8155, 10R8156, and 10R8157 cylinder packs in dealer parts stock.

Refer to attached Rework Procedure for details.

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Image1

Image2

Image3

SERVICE CLAIM ALLOWANCES

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Submit one claim for all cylinder packs inspected & reworked. 0.5 hours will be allowed for every two cylinder packs inspected & reworked. Ex. Two cylinder packs inspected & reworked = 0.5 hour claim. Four cylinder packs inspected & reworked = 1.0 hour claim

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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Inspection Procedure:

1. Inspect the package date code label on the outside of the box (Image 1.1.1) of all 10R8154, 10R8155, 10R8156, and 10R8157 cylinder packs in dealer parts stock. The first nine characters of the date code indicate the Day, Month, and Year. Determine if the date code falls in the range of D01M07Y10 through D04M11Y10 (01 July 2010 thru 04 November 2010).

- If the date code on the package IS within the date code range of D01M07Y10 through D04M11Y10 (01 July 2010 thru 04 November 2010), proceed to Step 2 of the Inspection Procedure.

- If the date code on the package IS NOT within the date code range of D01M07Y10 through D04M11Y10 (01 July 2010 thru 04 November 2010), mark the outside of the package to indicate it has been inspected according to this program, PI7#### / REBE6777, and return to dealer parts stock. No further action is required, the cylinder pack may be used "as-is".

Image1.1.1

2. Remove the cylinder pack from the packaging, if necessary, and inspect the alignment of the connecting rod cap to the notch in the piston skirt.

- If the alignment of the connecting rod cap resembles the left-hand side of Image1.2.1, proceed to the "Rework Process" below.

- If the alignment of the connecting rod cap resembles the right-hand side of Image1.2.1, mark the package to indicate that the cylinder pack has been inspected according to PI7#### / REBE6777, and return to dealer parts stock. No further action is required, the cylinder pack may be used "as-is".

Image1.2.1

Rework Process (Image1.3.1):

1. Confirm connecting rod cap and notch in piston skirt are oriented incorrectly.

2. If cylinder pack is still in packaging, remove cylinder pack from packaging.

3. Slide piston/rod assembly from cylinder liner until the pin and snap rings are exposed.

NOTE: Leave the piston inside the cylinder liner far enough to keep the rings compressed.

4. Remove one snap-ring and slide the piston pin far enough to relieve the connecting rod.

5. Rotate the piston rod assembly one half turn (180 degrees), install the piston pin and snap-ring.

6. Slide the piston/rod assembly into the cylinder liner.

7. Return the part to the original packaging, mark the package to indicate that the cylinder pack has been inspected according to PI7#### / REBE6777, and return to dealer parts stock. (not shown)