PSP TO REPLACE CYLINDER PACKS ON CERTAIN 980G WHEEL LOADERS; 824G, 825G, AND 826G COMPACTORS BECAUSE OF PISTON DEBONDING - PS5 592 - MAILED US AND CANADA, CACO, COFA, CAPL, CCL, COSA - REVISED 03/01 Caterpillar

March 27, 1999
(Revised March 2001)
SEBE6832-04
March 27, 1999
(Revised March 2001)
U-83
A-66
AU-50
S-47
H-31
O-75
After failure only PRODUCT SUPPORT PROGRAM TO REPLACE CYLINDER
PACKS ON CERTAIN 980G WHEEL LOADERS; 824G,
825G, AND 826G COMPACTORS BECAUSE OF PISTON
DEBONDING
1215   PS5592
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
"PS5590" as the Part number and "7755" as the Group
Number. Use "96" as the Warranty Claim Description
Code and use "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: This Revised Service Letter replaces the March 27,
1999 (Revised April 2000) Service Letter. Changes
have been made to the Termination Date, Parts Needed,
and the Action Required.

March 31, 2002

Machine engines with an aluminum piston may fail due to debond of
the iron ring band (iron band separation from the aluminum body).
Aluminum piston (116-8154) is considered to have failed if it is
unable to create compression due to a hole in the crown/crater or
has a loose or broken iron band in the crown.

Model Identification Number
***** Group 1 *****
980G  9CM1-Up (With Engine 41Z1-7270)
2KR1-Up (With Engine 41Z1-7270)
2SR1-Up (With Engine 41Z1-7270)
824G  4SN1-Up (With Engine 41Z1-7270)
825G  6NR1-Up (With Engine 41Z1-7270)
826G  7LN1-Up (With Engine 41Z1-7270)
***** Group 2 *****
980G  9CM1-Up (With Engine 41Z7271-8065)
2KR1660-Up (With Engine 41Z7271-8065)
2SR432-Up (With Engine 41Z7271-8065)
824G  4SN368-Up (With Engine 41Z7271-8065)
825G  6RN329-Up (With Engine 41Z7271-8065)
826G  7LN324-Up (With Engine 41Z7271-8065)
***** Group 3*****
980G  9CM1-Up (With Engine 41Z8066-12894)
2KR1804-Up (With Engine 41Z8066-12894)
2SR447-Up (With Engine 41Z8066-12894)
824G  4SN380-Up (With Engine 41Z8066-12894)
825G  6RN334-Up (With Engine 41Z8066-12894)
826G  7LN350-Up (With Engine 41Z8066-12894)

Quantit Part Number Description
y
***** Group 1 *****
6 0R9847 CYLINDER PACK
6 1663650 TUBE AS-OIL JET
6 1501156 BOLT -OIL JET
1 9Y1792 RETAINER
6 7W4487 WASHER
6 9Y7735 BEARING
6 9L9098 SEAL - NOZZLE CARBON DAM
***** Group 2 *****
6 0R9847 CYLINDER PACK
6 1663650 TUBE AS-OIL JET
1 9Y1792 RETAINER
6 7W4487 WASHER
6 9Y7735 BEARING
6 9L9098 SEAL - NOZZLE CARBON DAM
***** Group 3 *****
6 0R9847 CYLINDER PACK
6 1580449 TUBE AS-OIL JET
1 9Y1792 RETAINER
6 7W4487 WASHER
6 9Y7735 BEARING
6 9L9098 SEAL - NOZZLE CARBON DAM

Remove six tube as. - oil jet and bolts, six cylinder packs, six
fuel injection nozzle washers (nozzle to adapter). Inspect the
oil pump bypass spring retainer for correct part number. The
spring retainer should be 9Y1792.
Install six 0R9847 Cylinder Packs, six Tube As-Oil Jet and Bolts
(Torque 3/8 inch bolts to 25+/-6 Nm 18+/-4 lb ft) (Torque 7/16
inch bolts to 40+/-8 Nm 30+/-6 lbft), 9Y1792 Oil Pump Spring
Retainer if required. Install the six 7W4487 Fuel Injection
Nozzle Washers (nozzle to adapter) (black) (1.27 mm (0.050) inch
thick) and 9L9098 Carbon Dam Seal if required.
NOTE: Be sure to remove all carbon from bore and end of
injector adapter in cylinder head as the 7W4487 Washer
allows the nozzle to seat deeper into the adapter.
Install related gaskets and seals.

Product Caterpillar Dealer Suggested Customer
smu/age  Suggested
whicheve
r comes
first
Parts Labor Parts Labor Parts Labor
(D/N) Hrs Hrs (C/L) Hrs
(Cost)  (Sell)
0-4000 100% 50.0 0 0 0 0
0-48 mo
4001- 50% 35.0 0 0 37.5% 15.0
6000
0-48 mo
6001- 33.3% 20.0 0 0 50% 30.0
8000
0-48 mo
NOTE: This is a 50-hour job.

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